Mining Jaw Crusher Automation

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"Due to the functionality of the myRIO platform, we could include various elements (sensors, indicators) in the system configuration to increase dumping procedure safety and provide a crusher intelligent control system. We developed and installed the whole system within two months."

- Davit Zargaryan, 10X Engineering LLC

The Challenge:
Designing and deploying a mining jaw crusher intelligent drive and control system with haul truck traffic and safety dumping procedure management functionality.

The Solution:
Using the flexibility of the myRIO platform for environmental specifications to design a robust and compatible system in a short time period.

Author(s):
Davit Zargaryan - Find this author in the NI Developer Community
Vachagan Petrosyan - 10X Engineering LLC
Vahagn Aghababyan - 10X Engineering LLC

10X ENGINEERING LLC, founded in 2013, is an NI Alliance Partner. The company has knowledge and experience delivering innovative complex engineering solutions for RF products (units, devices, components), quality and line testing, custom-designed ATE system assembly, verification, and development. Our offering includes solutions for a variety of industrial sectors such as RF software defined radio, radio location, spectrum monitoring, and more. For every request we receive, we clarify project technical and software functional requirements, select RF measurement methodology, and follow hardware configuration procedures. If needed, we take responsibility for proving a concept and demonstrating the flexibility and reliability of our solution.

Problem Background and Solution

Our customer, Valex Group, is specified in mining and copper-molybdenum deposit exploitation. The ore is transported from the mine site by mining haul trucks to two jaw crusher stations. As the amount of ore brought from the open pit varies, the crusher stations must work efficiently to ensure the stability of ore processing and supply for the subsequent phases.

Mining operations use crushers, commonly classified by the degree to which they fragment the starting material. A jaw crusher uses compressive force to break particles. This mechanical pressure is achieved by the two jaws of the crusher. One jaw is fixed and the other reciprocates. A jaw or toggle crusher consists of a set of vertical jaws. One is a stationary jaw called a fixed jaw, and the other, called a swing jaw, moves back and forth by a cam or pitman mechanism. Crushers use energy, so optimizing the drive and management systems makes good economic sense. Equipment control and personnel safety in the dumping area is most important.

We designed the system to control the security processes. These items make the system functional:

  • Traffic management of heavy equipment (haul truck CAT 777) on the area of unloading (max number in dumping area should be two), to avoid traffic jams and emergencies
  • Mining crusher drive system to control jaw crusher depending on volume of raw in pocket

We need intelligent systems to control traffic and dumping procedure regulations. We propose two three-color traffic lights to address these issues. The system controls traffic light colors depending on both the number of trucks in the dumping area and the level of ore in the damp pocket.

The system configuration includes:

  • Two traffic lights
  • A control block and myRIO
  • LM 200 laser meter to measure the volume of raw in dump
  • A 433 MHz remote control
  • Two IR gates (2TX, 2RX)

Figure 1. System Scheme

Haul truck counting [Traffic light-1 Front 3-color (red, yellow, green) Beck (counter 3 segments). 

On the left and right sides of the road, on the column (height depends on the physical parameters of the truck, here we used CAT 777 as the haul truck) we placed pairs of receivers and transmitters sensors, which worked in the infrared range. When the truck passed, it caused the cut of the transmitter laser beam (Figure 2 shows the output of the sensor depending on the truck motion).

The myRIO device detected a signal, which provided an appropriate response as described in Table 1.

Traffic light -1 Number of cars
Green 0
Yellow 1
Red 2

                    Table1. Traffic light -1

Figure 2. IR Remote Control Sensor Output: A-Truck IN B-Truck OUT

In case of emergencies, the operator can help with the remote control in these ways:

  • Change color of traffic light
  • Increment, decrement, pause, or reset the counter

The seven-segment indicator shows information about the number of machines for further analytical processing.

Raw volume measurement [Traffic light-2 Front 3-color (red, yellow, green).

The current traffic light indicates the status of the jaw crusher and whether it can facilitate unloading a haul truck (connected with volume of raw in pocket). In dump pocket, the volume of ore measurement is done by a laser meter ABB LM200.

Table 2 shows the traffic lights -2 responses:

Traffic light -2 The volume of material
Green Raw volume in range/crusher ON
Yellow Raw volume out of range/crusher OFF
Red Emergency situation (by operator)

Table 2. Traffic Light -2

If the truck dump traffic light is red, the truck driver either waits for the green light before dumping on the grizzly, or immediately dumps the ore in a temporary stockpile nearby.

Figure 3. Dump Pocket

Due to the functionality of the myRIO platform, we could include various elements (sensors, indicators) in the system configuration to increase dumping procedure safety and provide a crusher intelligent control system. We developed and installed the whole system within two months.

Author Information:
Davit Zargaryan
Find this author in the NI Developer Community

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