Exploitable results
The OLGA size distribution analyzer consists of a matrix DTC camera (512 x 512 pixels) positioned above the conveyor. The camera selected has a short integration time to prevent any blur due to the motion of the materials, and it transmits the image to a processing unit. A tunnel is used to prevent any external light disturbances. The selected image processing unit is the EDIXIA IA 1000 model. The results are displayed on a video console.
The processing algorithm consists of 2 separate sections: preprocessing designed to improve the image characteristics; and processing allowing for extraction of significant parameters and based on the mathematical morphology of grey levels.
The analyzer performances may be summarized as follows:
repeatability: different analyzes performed on a single image provide identical results;
precision: several analyzes performed on a single sample resulted in an absolute scattering of approximately 3 units in terms of percentage in the various categories;
sensitivity: the analyzer detects variations of 5% in aggregate size;
measuring range: the analyzer measures aggregate sizes ranging from D to d, with D = size of coarsed grains, and d = max (D/15, 2 mm).
This device is intended to reconstruct the degree of wear of crushing components. The wear sensor, named KARINE, uses mathematical models characterizing the wear of the crusher on the basis of measurable values (power, output flow). These measurements are processed by a state reconstructor (Kalman filter). The resulting sensor provides information on the wear drift around the operating set point. If the wear drift exceeds a given threshold, the operator adjusts the opening of the crusher. A new operating set point is then defined and the wear drift is reinitialized.
This software program named LUCIE is designed to calculate an operating point for given equipment. It consists of the following modules:
Preprocessor:
An interface with operator provides the definition of given equipment based on user friendly graphic tools. This interface contains the icons corresponding to the basic machines comprising the quarry facilities.
Database:
The database contains the characteristic values of the different types of crushers and is used to calculate mathematical models for various crusher versions. Its access is open to enable the operator to enter the values relevant to his machinery.
Solver:
A simulation module has been designed to calculate an equilibrium point (in the sense of fluxes) by acting on the input flow of the equipment. This module provides the possibility of determining, for a given combination of settings of the various machines, the maximum allowable average input rate and of calculating the resulting production.
An optimization module has also been designed to minimize a criterion whose value is weighted by the operator to match his production requirements. Minimization of this criterion leads to the determination of optimum settings of the crushers, thereby fulfilling the production requirements.
Postprocessor:
The results are then displayed on a screen. These results show the setting values of the crushes calculated by optimization, the input flows and the size distribution at various points of the equipment.
LUCIE software runs on a personal computer (PC) and needs a mathematical coprocessor for optimization. A great number of trials have been done on real cases. These simulations have shown that results calculated by LUCIE software correspond to real values with good precision (around 10% for the flows at various points of the equipment).
This software program is designed to calculate automatically the command laws for given equipment, based on the prior definition of its structure and input output values supplied by the operator. The algorithms generated use a decoupling technique.
The software program runs on a IBM compatible personal computer (PC). It constitutes a prototype program designed to provide in a relatively automatic manner a description of the equipment as well as the generation of models and control algorithms; an industrial version of the software could be usefully applied by engineering firms or trade professionals.
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