REAL TIME VISIBILITY OF DUMPER LOAD TO SHOVEL OPERATOR

Abstract

ABSTRACT REAL TIME VISIBILITY OF DUMPER LOAD TO SHOVEL OPERATOR The present invention relates to a real-time monitoring system for mining operations that provides shovel operators with immediate and accurate feedback on dumper load conditions. The system comprises load sensors mounted on dumpers to measure material weight and a wireless communication module that transmits load data to the shovel operator's control panel. The shovel operator’s display interface provides real-time visibility of the load status, preventing overloading and underloading. The system enhances operational efficiency and safety by reducing accidents due to low visibility, optimizing material handling, and minimizing equipment wear. The invention is applicable to large-scale mining and construction operations where precise load monitoring is critical to improving productivity and safety. Fig.1

Specification

Description:FIELD OF THE INVENTION
The present invention generally relates to the field of mining and heavy equipment operations, particularly relates to improving the operational efficiency and safety of large-scale equipment, such as dumpers and shovels.

BACKGROUND OF THE INVENTION
When working with dumpers and shovels in large scale mining processes, the synchronization of implementing those huge machineries is an important factor that determines the effectiveness of the operation and the wellbeing of the employees. Earlier, the shovel operators were not aware of the condition of the dumpers that they are going to load. Some are listed below:

Overloading or Underloading: In the absence of proper load data, operators may tend to over specify or under specify the capacity of dumpers which is inefficient and could be very costly and perilous to the equipment and the overall utilization of resources.

Operational Delays: The time spent on stopping and checking loaded levels, which involve repetitive and time-consuming tasks of typing, also add to inefficiency of the process.

Safety Risks: Low visibility might result in an accident or collision of the equipment which would lead to disastrous consequences and risks to the lives of the operators and other people within the surrounding area.

The existing methods of load assessment have proven inefficient, leading to higher fuel consumption, increased equipment wear, and reduced productivity. Therefore, there is a need for a system that provides real-time visibility of dumper loads to shovel operators, ensuring accurate and safe material handling.

OBJECTS OF THE INVENTION
It is the primary object of the invention to provide a monitoring system to get immediate and accurate feedback on the state of the dumper load during mining or construction works.

It is another object of the invention to provide the shovel operators with real-time visibility of the load status of dumpers.

It is another object of the invention to minimize the risks of overloading and underloading through accurate load monitoring.

It is another object of the invention to reduce operational delays by ensuring timely feedback on dumper load levels.

It is yet another object of the invention to enhance the safety and efficiency of mining operations by integrating load sensors and wireless communication technology.

SUMMARY OF THE INVENTION
To meet the objects of the invention, it is disclosed here a real-time load monitoring system for mining and construction operations, comprises: one or more load sensors; a wireless communication module; a control panel; a graphical user interface; and a feedback mechanism, wherein the load sensors are installed on a dumper to measure the weight of material loaded on the dumper, the wireless communication module is connected to the load sensors for transmitting load data, the control panel located in the shovel operator's cabin is configured to receive and display the real-time load data transmitted from the dumper, the graphical user interface is integrated into the control panel for providing real-time visibility of dumper load conditions, and the feedback mechanism alerts the operator of overloading, underloading, or uneven load distribution; and wherein the load sensors are positioned symmetrically on the dumper and are calibrated to ensure accurate load measurement.

Further discloses here a method for real-time monitoring of dumper loads in mining operations, comprising the steps of: installing one or more load sensors on a dumper to measure material weight; connecting the load sensors to a wireless communication module for transmitting load data; continuously transmitting real-time load data from the dumper to the shovel operator's control panel; displaying real-time load status on the control panel through a graphical interface; and alerting the shovel operator when the dumper load exceeds or falls below pre-set thresholds, or when the load distribution is uneven.

BRIEF DESCRIPTION OF THE FIGURES
Fig.1 is the simplified architecture of the load cell measurement system using an analog-to-digital converter.
Fig.2 is an image of amplifier.
Fig.3 is the schematic representation of placement and structural arrangement of the load cell on the dumper.
Fig.4 is the circuit diagram showcasing the interaction between different modules of the present system.
Fig.5 is an image of the prototype of the system.

DETAILED DESCRIPTION OF THE INVENTION
The invention provides a real-time monitoring system that communicates dumper load information to shovel operators. Load sensors installed on the dumpers measure the material weight, and this data is transmitted wirelessly to the shovel operator's cabin. The system includes a graphical interface that displays real-time load information, allowing operators to make informed decisions during the loading process. This prevents overloading and underloading, increases operational efficiency, and improves safety by reducing accidents due to poor visibility.

The system uses strategically placed load sensors on the dumpers, connected to a wireless communication module. Data is processed and displayed on the shovel operator's control panel, providing continuous feedback on the load condition. This system significantly enhances material handling in mining operations.

The invention presents a monitoring system that provides immediate and accurate feedback on the state of the dumper load during mining or construction works. Traditional approaches of communicating load information entails using such data which is delayed; this may cause inefficiencies and even danger of overloading or under loading.

The operations in the mining and construction industries require efficiency in the handling of materials as this is significant in increasing production and also ensuring safety in the process. Typically, shovel operators have only been able to determine the load status through sight estimation or by asking dumper drivers, which may be inaccurate and increases the probability of compromising on safety. This system checks the amount of material that has been filled in to ensure that it is adequate and not more in order to avoid wastage and also to avoid straining some parts of equipment.

Work Efficiency Analysis: With and Without Real-time Dumper Load Monitoring System
This analysis looks at the difference in productivity of mining and construction activities when the shovel operator has access to a real time dumper load monitoring system and when the shovel operator has no access to it. The benchmark is, therefore, based on the organization's performance indicators including operational accuracy, productivity, efficiency and cost control.

Without Real-time Monitoring
With Real-time Monitoring
Loading Accuracy Low (frequent underloading/overloading) High (precise and consistent loading)
Downtime High (frequent adjustments) Low (minimal adjustments)
Coordination Inefficient (delays) Efficient (smooth operations)
Fuel Consumption High (inefficient loading practices) Low (optimized loading practices)
Operator Fatigue High (constant monitoring) Low (system-assisted monitoring)
Material Handling Sub-optimal handling Optimal handling
Maintenance Costs Frequent equipment damage Low equipment damage

Load Cell HX711:
The HX711 is a precision 24-bit analog-to-digital converter (ADC) designed for weigh scales and industrial control applications to interface directly with a bridge sensor. The load cell, which measures the weight or force, outputs an analog signal that the HX711 converts into a digital signal for processing.

Architecture Diagram
Figure 1 is a simplified diagram showing the architecture of a load cell measurement system using the HX711.

HX711 Pin out:
VCC: Power supply (usually 2. 7V - 5)
-> GND: Ground.
-> DT (Data): Operational data line linked with the micro controller.
->SCK (Clock): Clock line which is connected to the micro controller.
-> E+ and E-: Bolted to the Excitation + /VCC and Excitation -/GND of the load cell.
-> A+ and A-: Bolted to the Signal+/Output+ and the Signal-/Output- terminals of the load cell.
HX711 Amplifier
The output signal generated by the load cell is usually of the order of mill-volts, and thus requires an amplifier (Figure 2) to amplify the signal so as to subsequently be converted to an analog to digital format for processing.

Load Cell Placement
(Trial and Test method)
It is also important that load cells be properly positioned so as to accurately measure the weight applied on them. Below are the key factors to consider, when positioning the load cell.

This should be done with personal precision and no references:
1)Symmetrical Placement: In order to balance the load on the load cells it is crucial that they are located in a symmetrical manner with the center of the load.
2)Stable Surface: Place/fix the mount load cells on a flat surface in order not to tilt the load cell because this will increase inaccurate results.
3)Isolation from Side Loads: Place load cells in a way so that they do not get side loads or twisting force because these affects the measurements.
4)Environmental Protection: The environmental conditions such as moisture, dust, and temperature should not directly influence the functionality of the load cells.
5)Consistent Contact: Make sure that the load cell maintains conical touch with the load and the surfaces must be smooth and knob less.
6)Number of Load Cells: Mount as many load cells as will cover the area of the load platform, the number usually ranges between four for square or rectangular platforms.
In Figure 3, one load cell is included.

Working Principle
Place a known weight on the load cell. Then, do the calibration with the raw value displayed at serial monitor. Now, place any object on load cell which weight is unknown. The output of load cell will be in mill- volt. So, its output is feed to amplifier and analog to digital converter before providing to the micro controller (i.e Arduino). After proper calibration the weight of that unknown object is displayed in 16*2 LCD display. (Shown in Figure 4)

Working of the Invention
The purpose of this invention (Figure 5) is to improve the mining process by utilizing a robotic shovel connected with Bluetooth equipment with real time load visibility.

Robotic Shovel with Load Sensors: The shovel is equipped with advanced sensors that accurately measure the weight and distribution of the material being loaded. These sensors are strategically placed to capture real-time data, ensuring precise measurement of the load.
Bluetooth Communication System: The shovel is connected to a Bluetooth communication system, enabling wireless data transmission. This allows the load data collected by the sensors to be sent directly to the shovel operator's display unit as well as to the shovel itself. This seamless communication ensures that both the operator and the shovel are always updated with the current load status.

Operator Display Unit: The operator has a dedicated display unit, which can be a handheld device or integrated into the control cabin. This unit receives real-time data from the shovel via Bluetooth, providing instant feedback on the load status. The display shows the current weight of the load on the shovel, alerting the operator when the load is nearing capacity or if there is an uneven distribution. This helps the operator make informed decisions on loading and unloading processes.

Control Interface: The shovel operator uses a control interface to operate the robotic shovel. This interface is designed to be intuitive, allowing for precise control over the shovel's movements. The Bluetooth connectivity ensures that commands are executed promptly, and the operator can adjust the shovel's actions based on the real-time load data displayed.

Real-Time Feedback Loop: As the shovel loads material, the sensors continuously update the load weight, and this information is transmitted via Bluetooth to both the shovel and the operator's display unit. This real-time feedback loop ensures that the operator is always aware of the current load status, allowing for dynamic adjustments to optimize loading efficiency and safety.

Safety and Efficiency Enhancements: The real-time visibility of load data helps prevent overloading and underloading, reducing the risk of equipment damage and operational delays. By ensuring proper load distribution, the system enhances overall safety and efficiency in mining operations. The robotic nature of the shovel reduces the need for manual intervention, minimizing human error and increasing the precision of loading tasks.

By combining robotic automation, real-time data transmission, and intuitive control interfaces, the present invention significantly improves the efficiency, safety, and productivity of mining operations.

Experiment and Results
Month 1: Initial Implementation and Calibration
Weeks 1-2: System Setup, Initial Testing, and Training
• Installation and Calibration: To implement the wireless communication and load sensing system, the robotic shovel was installed at mining site. Sensors were checked so as to ensure correct identification of load irrespective of the type of surface it was on.
• Initial Testing: Basic check-up and system connectivity were checked prior to using the system. Trial runs of the journal on a variety of terrains helped to authenticate performance.
• Operator Training: Shovel operators were also trained on the use of control interface and reading of real time data. Finally, further elementary feedback was gathered in order to sort out some of the possible problems.

Weeks 3-4: System Optimization and Full-Scale Operation
• Adjustments and Integration: Changes based on operator feedback included amendment of the settings of the sensors as well as the interface. Extensions to the software included the interfacing with other mine management software to provide an overall view.
• Operational Launch: The system was put again all for distinctive utilization as a part of the civil service. The basic performance of the Box was assessed on a daily basis in order to maintain its high level of functionality and to have the proper response to recently emerged problems.

Month 2: Full Operation and Continuous Improvement
Weeks 1-2: Performance Monitoring and Feedback Collection
• Data Analysis and Feedback: Information collected on the overall first month was studied to check how it affected efficiency, safety, and productivity. The issues that were seen to recur was collected through the suggestion boxes from operators.
• Operator Insights and Optimization: Some of the information gathered from the operators were used to fine tune the system to ensure both the real time load monitoring and the Bluetooth control was at their best.

Weeks 3-4: Operational Review and Planning
• Routine Maintenance Checks: Periodical checkups of the robotic shovel and the sensors were done to ensure it would keep on operating effectively and efficiently.
• Comprehensive Review and Future Planning: As part of the evaluation process an assessment on performance, impact on costs and safety was made of the system. The opportunities for further development, upgrading the existing training programs, and the strategy for site expansion were worked out.

By the end of the above stated time, much effectiveness and safety and also the productivity of the system could have increased while the increase would have been constantly checked and managed. Depending on technology such as 5g a lot of information can be provided, transmitted and delays are kept to a minimum, thereby enhancing the accurate movement of the huge and complicated machines as well as control of safety.

Applications and commercialization:
The robotic shovel system can be widely applied in mining operations to enhance efficiency, safety, and productivity by providing real-time load data. Its commercialization potential includes integration into existing mining equipment fleets and offering as a standalone product or service, contributing to cost savings and operational optimization in the mining industry.
 
, Claims:We Claim:

1. A real-time load monitoring system for mining and construction operations, comprises:
one or more load sensors;
a wireless communication module;
a control panel;
a graphical user interface; and
a feedback mechanism,
wherein the load sensors are installed on a dumper to measure the weight of material loaded on the dumper, the wireless communication module is connected to the load sensors for transmitting load data, the control panel located in the shovel operator's cabin is configured to receive and display the real-time load data transmitted from the dumper, the graphical user interface is integrated into the control panel for providing real-time visibility of dumper load conditions, and the feedback mechanism alerts the operator of overloading, underloading, or uneven load distribution; and
wherein the load sensors are positioned symmetrically on the dumper and are calibrated to ensure accurate load measurement.

2. The real-time load monitoring system as claimed in claim 1, wherein the load sensors are placed in a manner that isolates them from side loads, twisting forces, and environmental influences, thereby ensuring accurate measurement under varying operational conditions.
3. The real-time load monitoring system as claimed in claim 1, wherein the wireless communication module utilizes Bluetooth or other wireless technology to transmit real-time load data from the dumper to the control panel in the shovel operator's cabin.

4. The real-time load monitoring system as claimed in claim 1, wherein the system comprises an analog-to-digital converter connected to the load sensors, which converts the analog load signals into digital data for transmission to the control panel.

5. The real-time load monitoring system as claimed in claim 4, wherein the analog-to-digital converter is connected to an amplifier to enhance the load signals prior to conversion for improved accuracy in load measurement.

6. The real-time load monitoring system as claimed in claim 1, wherein the control panel comprises a user-adjustable interface that allows the operator to modify alert thresholds for overloading, underloading, and uneven load distribution.

7. A method for real-time monitoring of dumper loads in mining operations, comprising the steps of:
installing one or more load sensors on a dumper to measure material weight;
connecting the load sensors to a wireless communication module for transmitting load data;
continuously transmitting real-time load data from the dumper to the shovel operator's control panel;
displaying real-time load status on the control panel through a graphical interface; and
alerting the shovel operator when the dumper load exceeds or falls below pre-set thresholds, or when the load distribution is uneven.

8. The method as claimed in claim 7, wherein the load sensors are symmetrically positioned on the dumper and are isolated from external mechanical and environmental factors to provide accurate load measurement.

9. The method as claimed in claim 7, wherein the wireless communication module transmits the real-time load data via Bluetooth technology to both the shovel operator's control panel and the shovel's control system.

10. A robotic shovel system for mining operations, comprises:
a shovel equipped with load sensors to measure the weight and distribution of material being loaded;
a wireless communication system for transmitting load data from the sensors to the shovel operator's control panel; and
a control interface for the shovel operator, enabling real-time adjustments based on load data,
wherein the shovel and the control panel are in continuous communication, providing real-time feedback to the operator on the load status for optimizing loading operations.

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