UltraTech Cement Limited

Unit: Hirmi Cement Works - 493195, Raipur (Dist.), Chhattisgarh

At From: Sandeep Verma To: Shri Chetan Shrivastav
DH- Mechanical Unit Head, HCW
Date: 26.05.2021 Through: Shri. P.K. Dad
FH Technical
Sub: Digital initiative for large size boulder detection in LS crusher
HCW, we have L&T make lime stone crusher. While crushing of lime stones in crusher, sometimes
large stones (>1400*1300*1100 mm3) are coming on the Apron conveyor which further get jammed
at the discharge chute of the Wobbler. When any large stone makes jamming in the chute, it takes 3-4
hrs. for the removal of that stone from inside of the chute manually which is very risky and time
consuming. Also it leads to production loss.
So to avoid this loss to the industry, we have proposed a digital system for the early detection
of large LS boulder if present. This system is basically a vision automated system which will measure
the dimensions of each boulder by continuous video processing. Then from this video, dimension of
each boulder will be calculated with the help of a software. When the dimension of the boulder will
be more than 1.4 m, the Apron conveyor will stop without allowing the large boulder to enter into the
discharge chute of Wobbler.
So by implementing this technology we can enhance our productivity to optimum efficiency for
the smooth flow of the material and thus process. The following inputs pertaining to the
requirements have been obtained from the problem and have been applied for designing the
proposed solution.
1. Check for large stones on the conveyor.
2. Integrate the vision results with conveyor.
3. Stop the conveyor if size of stone >1.4 meters is found.
The proposed setup consists of 2 cameras looking at different portions of the conveyor.
Camera will monitor the object continuously. The acquired 3D images from the camera are processed
to check for any stone with size greater than 1.4 meters.
● Stones are moving on the conveyor.
● Camera is placed from height to monitor the stones moving.
● Camera captures the images of the moving stones and are processed to identify the large
stones.
● Vision results are passed to the PLC and stops the conveyor if a large stone is detected.
We have contacted REDBOT INNOVATION PVT LTD regarding this and discussed about both technical
as well as commercial aspects in detail. The company has made a deal of 10 lacs and will take 5 lacs in
advance and rest after successful completion of the project without any fail.

Kindly accord your approval.

Regards,

P K Dad Sandeep Verma Akhilesh Khare

FH- Tech DH- Mech DH- E&I

Enclosed:
• Detailed arrangement drawing, cost estimation