Automation of

Stacker/Reclaimer

FLSmidth® BulkExpert™
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FLSmidth® BulkExpert™
Operational challenges
Stockyards around the globe are typically
facing the same daily operational
challenges that affect the overall
profitability.
These challenges, which represent an
unexploited optimisation potential, are
more than often related to factors which
are within our control but not always
sufficiently or optimally addressed, -
factors like:
• Non constant operator performance
• Complex planning and coordination of
operation during and between shifts
• Operator “errors” rendering the
machines unavailable
• Excessive manual tidying-up of piles
• Increased maintenance caused by
equipment overload
• Insufficient information relating to the
state and content of the stockyard
• Environmental interferences (weather,
dust, etc.)
The variety of operating methods and
the multiplicity of material’s has
traditionally made it difficult to rely on
anything else but skilled operators
and to some extent semi-automatic or
remote systems. However with the
patented FLSmidth® BulkExpert™
technology it will now be possible to
implement a completely unmanned
operation for any combination of
Stacker/Reclaimer.
The Solution
The FLSmidth® BulkExpert™ system
uses a 3D laser scanning system
combined with a dedicated RTK-GPS
array to produce a real time full
terrain information of the stockyard.
The real-time information is generated
during normal operation and does not
require dedicated and non-productive
scans of the piles. The terrain
information is used as a basis for the
expert system software to pass on the
calculated operating commands to
any Stacker/Reclaimer that is
controlled by the FLSmidth®
BulkExpert™ system.
As the FLSmidth® BulkExpert™ system
is able to replace the commands
normally given by the machine
operator with centimeter accuracy it
can eliminate problems like “air
reclaiming” and “ground digging”. In
addition all possible collision hazards
are continuously monitored during
stacking or reclaiming based on the
terrain database and additional
instrumentation. This overall
contributes to low mechanical wear
and tear and prevention of accidents.
Due to the application of the
patented technologies the FLSmidth®
BulkExpert™ system is classified as a
fully automated system which only
requires one operator present in the
central control room (CCR) to control
a complete stockyard.
The CCR operator is only required to
enter the job parameters (e.g. material,
amount, location) for the relevant
Stacker/Reclaimer.
The Stacker/Reclaimer will automatically
move to the correct location and will
start the job by selecting the most
beneficial position and bench in order to
achieve an optimised result. To ensure
that the safety is not compromised
during automatic operation all machine
interlocks remain active and unaltered
so that the CCR operator can
concentrate on the overall operation of
the stockyard.
In addition to the unmanned operation
of the Stacker/Reclaimers the 3D terrain
information can be used for terrain
management and job planning, since it
allows the CCR operator to always have
a real-time overview of the stockyard.
This information is visually presented
using color coding for different heights
of stockpiles as well as the volumetric
sizes that can be used for estimation of
the stockyard tonnage.
Capturing the potential
Capturing the optimisation potential is
highly dependent on parameters like;
stockyard layout, mode of operation,
and installed equipment on your
stockyard. Your specific stockyard is
customised to suit your demands and
thus needs a customised approach to
identify and capture the optimisation
potential. Because of this we
recommend that the design of
and the decision to install a
FLSmidth®BulkExpert™ system should be
based on a thorough analysis of the
conditions prevalent at your specific site.
The analysis is part of an on-site
feasibility study that comprises;
gathering of data, observation of daily
operation, and inspection of the
installed equipment’s state, performance
and suitability. All this information is
complied into concluding
recommendations focusing on; areas of
improvement, financial viability, and
specification of requirements to the
installed equipment.
A natural step following the feasibility
study is the specification of the actual
project scope and execution including
implementation and commissioning of
the FLSmidth® BulkExpert™ application
as well as adaptation of existing
equipment if necessary. FLSmidth offers
to undertake some or all of the tasks
based on your preferences while
ensuring that they are carried out in a
manner that minimises the disturbance
of the daily operation.
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Copyright © 2013 FLSmidth A/S. ALL RIGHTS RESERVED. FLSmidth is a (registered) trademark of FLSmidth A/S. This brochure makes no offers, representations
or warranties (express or implied), and information and data contained in this brochure are for general reference only and may change at any time. www.flsmidth.com