Material separation and conveyance using tuned waves

Systems, methods and computer readable media for material separation and conveying using tuned waves are disclosed.

FIELD

Embodiments relate generally to material separation and, more particularly, to systems and methods for separating materials using tuned waves.

BACKGROUND

In aggregate ore separation, current industry standard practices may employ chemically intensive processes and methods such as shaker tables and hammers. This may be a somewhat primitive method of trying to physically separate materials (e.g., shake out the ore). Some conventional systems may be operating within a limited range of frequency separation (via pressure disturbance through mechanical waves generated by physical contact with tables and hammers). This can result in essentially one frequency, possibly un-tuned to the objects they are attempting to separate, providing only one degree of freedom. Due to this, the efficiency and effectiveness is diluted even further when aggregate ore is presented in multiple mediums. Not only are conventional techniques more energy intensive than might be necessary and may be more water intensive, but an inability to tune frequencies to very specific ranges for most efficient separation can result in significant loss of ore that was unable to be separated at all for use.

Embodiments were conceived in light of the above-mentioned problems and limitations, among other things.

SUMMARY

Some implementations can include systems and methods for separation, stratification and/or conveyance of aggregate ore, in various mediums, by a technique of tuning a pressure disturbance known as mechanical waves. Some implementations can accomplish this without the energy intensive process of generating said waves via physical contact and also allows multiple degrees of freedom of the aggregate ore. This process may be accomplished via the configuration of relatively inexpensive existing technologies provided in an adjustable platform, that can generate the frequencies that can travel through the various mediums (air, water, etc.) being employed without the need for physical contact (and may be optionally communicated via a plate).

The process can include administering a stimulus of sound wave energy to a mixture (or matrix) of heterogeneous materials, then exploiting the differences in the individual motive response values of material types. The stimulation control values (or parameters) can be altered to promote the greatest differential in response values between different material types, which can, in turn, determine the most effective physical configuration of the process hardware, and the most feasible method for final mechanical separation. Differences in material types to be separated, size to be separated, rate of separation, conveyance needs or the like, all have notable impacts on the overall settings, configuration and physical appearance of the separation equipment and scale, but the process itself may be similar.

Process settings (or parameters) can include number of output devices, power output, frequency, amplitude, signal duration, and phase of output signal to each device, physical orientation of output devices, angle of incidence of each output device to a plate, plate type/configuration (e.g., plate material, plate thickness, plate type or the like), inclination angles of two axis of the apparatus, and, in the case of wet separation, evacuation fluid flow rate, pressure, and direction of fluid flow. The frequencies/wavelengths being generated can then be tuned to specific ranges, based on the reactions of materials to be separated. Materials of different types may have differences in measurable response values. The simulation can be modified in order to create the greatest differential between response values, which will determine the optimal settings, scale, and configuration of system hardware. Differences in material types, size, and rate of separation, as well as moisture content, will have notable impacts on the above-mentioned parameters, but the process will be similar. Process settings can include number of output devices, frequency, amplitude, phase of output signal, duration of output signal, physical orientation of output devices, two axis of inclination of plate, and in the case of wet separation, fluid flow rate, pressure, and direction of fluid flow. Some implementations may also include automated changes in process control points based either on elapsed time, or feedback from sensory devices. Some implementations may include “pinging” the resonant frequency of the materials. The principal behind this process is that any object when sharply struck, or in this case pinged, will emit its own resonant frequency. Therefore, objects of varying make-up may emit varying frequencies.

By pinging objects with frequencies tuned for their specific make-up, the frequency emissions of objects can now be maintained. When more than one material type is being separated, as with aggregate ore, each individual material type is being continually pinged so as to cause that material to resonate at its corresponding individual resonant frequency. This can cause each material to naturally fall into its respective bandwidth. A material, upon receipt of a concussive strike, will emit a resonant frequency, possibly unique to that material type. Material characteristics (e.g., density, size, weight, surface texture, or the like) may define or influence material measurable response values. These response values may then be used to determine the optimal values of the administered process stimulation. For example, if a material has a response duration (e.g., frequency emission) of 20 milliseconds, which is to be separated from another material with a response duration value of 10 milliseconds, then a 50 Hz output signal would maintain a constant response of the first martial type, but the second material type would be in an unresponsive state for 10 ms, then in a responsive state for 10 ms. This causes the stratification of any aggregate ore for purposes of claiming or reclaiming ore materials that current industry standard methods may have not addressed in an efficient or cost productive manner.

The principal behind this process is that any object when sharply struck, or in this case pinged, will emit its own resonant frequency. Therefore, objects of varying make-up may emit varying frequencies. By pinging objects with frequencies tuned for their specific make-up, the frequency emissions of objects can now be maintained. When more than one material type is being separated, as with aggregate ore, each individual material type is being continually pinged so as to cause that material to resonate at its corresponding individual resonant frequency. This can cause each material to naturally fall into its respective bandwidth. Frequency emission only represents one of many measurable responses having values that may change based on material properties. If the response value of material travel in height has a greater difference than the frequency emissions, then this particular response value may be targeted as it would provide the largest range between differing material reactions.

The relationship between materials may act as its own motivating force. For example, a contained mixture of same sized materials of differing densities would naturally lead to the denser material settling beneath the less dense material when exposed to vibratory motivation. However, based on process control parameters the material stratification may be reversed, if desired.

In another example, if materials of the same size are of a different shape e.g. cubes and spheres, then the cubes may agglomerate as their flat sides prohibit motion in one degree of freedom, so the spheres would be ejected from the cube agglomeration, and form an agglomeration of spheres.

In yet another example, when materials are separated based on texture, rough materials may encounter more friction than smooth materials, and may lag the smooth materials when traveling over a distance. When materials are to be separated based on size, the entire mixture itself can effectively serve as a dynamic screen, where materials pass between air gaps and result in a coarse to fine progression.

Delivering multiple frequencies at once can add multiple degrees of freedom. For example, this can be observed as stratification of materials by type. Once stratified, the materials can then be mechanically separated.

Some implementations can include a system comprising a controller programmed to separate materials using tuned waves, and an input device configured to measure material response to stimulation. The system can also include an output device configured to generate tuned waves based on one or more control signals received from the controller.

The controller can be configured to provide independent control over output signals to each output device. The controller can be configured to control one or more of a frequency, an amplitude, signal phasing, and signal duration of the one or more control signals.

The system can further include a plate configured with a two-axis of inclination and disposed so as to communicate the tuned waves from the output devices. The controller can be further configured to control one or more of fluid flow, fluid pressure, and fluid flow direction for wet material separation/conveyance.

The controller can be configured to perform operations. The operations can include providing material via a material hopper, and configuring a controller with material separation/conveyance parameters based on one or more components of the material. The operations can also include generating, at the controller, one or more modulated signals in accordance with the parameters, each modulated signal corresponding to an output device. The operations can further include amplifying the modulated signals, and supplying the amplified modulated signals to an output device. The operations can also include causing the material to be separated in response to application of the modulated signals from the output device via a resonator plate.

The controller can be further configured to receive a feedback signal from a feedback sensor and provide the feedback signal to the controller. The controller can be further configured to adjust, with the controller, the modulated signal based on the received feedback signal.

Some implementations can include a method including providing material via a material hopper, and configuring a controller with material separation/conveyance parameters based on one or more components of the material. The method can also include generating, at the controller, one or more modulated signals in accordance with the parameters, each modulated signal corresponding to an output device. The method can further include amplifying the modulated signals and supplying the amplified modulated signals to an output device. The method can also include causing the material to be separated in response to application of the modulated signals from the output device via a resonator plate.

The method can further include receiving a feedback signal from a feedback sensor and providing the feedback signal to the controller. The method can also include adjusting, with the controller, the modulated signal based on the received feedback signal. The method can further include orienting one or more of the output devices to a predetermined angle of incidence via a gimble corresponding to each output device.

The feedback sensor can include an ultrasonic sensor. The method can also include moving each separated components of the material to a respective output chute.

Some implementations can include a nontransitory computer readable medium having stored thereon instructions that, when executed by a processor, cause the processor to perform operations. The operations can include providing material via a material hopper, and configuring a controller with material separation/conveyance parameters based on one or more components of the material. The operations can also include generating, at the controller, one or more modulated signals in accordance with the parameters, each modulated signal corresponding to an output device. The operations can further include amplifying the modulated signals, and supplying the amplified modulated signals to an output device. The operations can also include causing the material to be separated in response to application of the modulated signals from the output device via a resonator plate.

The operations can also include receiving a feedback signal from a feedback sensor and providing the feedback signal to the controller. The operations can further include adjusting, with the controller, the modulated signal based on the received feedback signal. The operations can also include orienting one or more of the output devices to a predetermined angle of incidence via a gimble corresponding to each output device.

The feedback sensor can include an ultrasonic sensor. The operations can also include moving each separated components of the material to a respective output chute.

DETAILED DESCRIPTION

In general, material separation using tuned waves can include energizing an aggregate material with a specific frequency or set of frequencies. The frequency can be determined by measuring a physical response of the aggregate material to output device stimulation and receiving the response via an electrical and/or software interface and storing the received response for integration into a final output profile of the tuned wave separation system.

An example frequency bandwidth can be on the order of less than or equal to about 200 Hz, for example. An actual bandwidth can also be determined empirically based on testing of material responses.

In operation, output device (e.g., acoustical emitter) modulation is determined by one or more software controlled output signals in accordance with the above-mentioned frequency response. Output device physical orientation can be determined by a geometric relationship between the emitter and aggregate material present for separation. For example, outputs may be phased so that no more than120degrees of separation will exist for any one of the emitters within the physical machine structure. Some implementations can be used to create a vortex of sound (or tuned wave energy) in order to separate aggregate material.

FIG. 1is photograph of an example wet aggregate100showing a first material portion102and a second material portion104having been separated using an embodiment of the system described herein.FIG. 2is a photograph of an example dry aggregate200showing a first material portion102and a second material portion104having been separated using an embodiment of the system described herein.

FIG. 3is a diagram of an example system300for separating materials using tuned waves in accordance with at least one embodiment. The system300includes a mixed material supply302, a separator304including a plate and one or more tuned wave output devices, a first material chute306and a second material chute308.

FIG. 4is a diagram of an example system400for separating material using tuned waves in accordance with at least one embodiment. The system400includes a power supply402, a human-machine interface404, a communications link406and a central processing unit408. The system400also includes a file storage/retrieval system410(e.g., database), data modulation and recipe parameter control module412.

In operation, the processor408can output a modulated signal414to an amplifier416. The amplified signal can be supplied to a wave generator420, which can supply an amplified output422to a resonator plate424in contact with material to be separated (or conveyed)426.

The system400can also include a feedback loop418for providing a feedback channel so that the processor can automatically adjust system parameters.

FIG. 5is a diagram of an example process flow500for separating materials using tuned waves in accordance with at least one embodiment. The process500includes providing material to be separated or conveyed502and subjecting the material to mechanical waves504.

The waves are received by a receiving device506and used to stimulate the material508. The stimulated material may exhibit vibration or other motion based on mechanical wave energy absorption, reflection and density of material510. The material can be guided via a manual or automatic guide system to collection bins512.

FIG. 6is a diagram of an example computing device600that can be configured for material separation and/or conveyance using tuned waves in accordance with some implementations. The computing device600includes a processor602, operating system604, memory606and I/O interface608. The memory606can include a material separation and/or conveyance tuned wave application610and a database612(e.g., for storing tuned wave parameters or the like).

In operation, the processor602may execute the material separation and/or conveyance tuned wave application610stored in the memory606. The material separation and/or conveyance tuned wave application610can include software instructions that, when executed by the processor, cause the processor to perform operations for material separation and/or conveyance tuned wave in accordance with the present disclosure (e.g., the material separation and/or conveyance tuned wave application610can perform one or more of steps402-426and/or502-512described above and, in conjunction, can access the database612). The material separation and/or conveyance tuned wave application610can also operate in conjunction with the operating system604.

FIG. 7is a diagram of an example system for material separation and conveyance using tuned waves in accordance with at least one embodiment. The system includes a material hopper that feeds material onto a separation table. The material can be separated into three streams as shown inFIG. 7. The system can also include adjustable height feet. The system can include an ultrasonic sensor disposed on one or more material stream guide members.

FIG. 8is a diagram of an example output wave pattern for material separation and conveyance using tuned waves in accordance with at least one embodiment. The wave pattern can include a plurality of output devices generating waves at different frequencies (shown as ring spacing) and power levels (shown as ring size) as shown inFIG. 8.

FIG. 9is a diagram of an example output device placement and orientation in a system for material separation and conveyance using tuned waves in accordance with at least one embodiment. Output Device #1 (B) is shown oriented generally perpendicular to the resonator plate. Output Device #2 (C) is oriented generally perpendicular to the resonator plate and spaced a distance below the plate. Output Device #3 (D) is oriented by a gimble (E) so as to have a longitudinal direction of the output wave at an angle of incidence to the resonator plate.

FIG. 10is a diagram of an example system for material separation and conveyance using tuned waves in accordance with at least one embodiment. The system includes a material hopper (A), a fluid nozzle (B), an ultrasonic sensor (C) to sense material and provide feedback to a controller, a plate (D), and adjustable legs (E).

FIGS. 11-13are diagrams showing various views of an example system for material separation and conveyance using tuned waves in accordance with at least one embodiment.

In addition to separating material, the tuned wave methods and systems described herein can be used to convey material. While examples have been described in terms of separating one or more materials from an aggregate material, it will be appreciated that other types of materials can be separated and/or conveyed using tuned wave systems and methods as described herein, such as waste streams (trash and/or recycling streams), food products, agricultural products and the like. In general any material where a need may exist to separate constituents (or convey material) may be processed using an implementation of the tuned wave separation/conveyance techniques described herein.

It will be appreciated that the modules, processes, systems, and sections described above can be implemented in hardware, hardware programmed by software, software instructions stored on a nontransitory computer readable medium or a combination of the above. A system as described above, for example, can include a processor configured to execute a sequence of programmed instructions stored on a nontransitory computer readable medium. For example, the processor can include, but not be limited to, a personal computer or workstation or other such computing system that includes a processor, microprocessor, microcontroller device, or is comprised of control logic including integrated circuits such as, for example, an Application Specific Integrated Circuit (ASIC). The instructions can be compiled from source code instructions provided in accordance with a programming language such as Java, C, C++, C#.net, assembly or the like. The instructions can also comprise code and data objects provided in accordance with, for example, the Visual Basic™ language, or another structured or object-oriented programming language. The sequence of programmed instructions, or programmable logic device configuration software, and data associated therewith can be stored in a nontransitory computer-readable medium such as a computer memory or storage device which may be any suitable memory apparatus, such as, but not limited to ROM, PROM, EEPROM, RAM, flash memory, disk drive and the like.

Embodiments of the method and system (or their sub-components or modules), may be implemented on a general-purpose computer, a special-purpose computer, a programmed microprocessor or microcontroller and peripheral integrated circuit element, an ASIC or other integrated circuit, a digital signal processor, a hardwired electronic or logic circuit such as a discrete element circuit, a programmed logic circuit such as a PLD, PLA, FPGA, PAL, or the like. In general, any processor capable of implementing the functions or steps described herein can be used to implement embodiments of the method, system, or a computer program product (software program stored on a nontransitory computer readable medium).

Moreover, embodiments of the disclosed method, system, and computer readable media (or computer program product) can be implemented in software executed on a programmed general purpose computer, a special purpose computer, a microprocessor, or the like.

It is, therefore, apparent that there is provided, in accordance with the various embodiments disclosed herein, methods, systems and computer readable media for material separation and conveyance using tuned waves.

While the disclosed subject matter has been described in conjunction with a number of implementations, it is evident that many alternatives, modifications and variations would be, or are, apparent to those of ordinary skill in the applicable arts. Accordingly, Applicants intend to embrace all such alternatives, modifications, equivalents and variations that are within the spirit and scope of the disclosed subject matter.