Delayed control
The crushing mode decision is made after the material flow has already changed.
Result: equipment works blindly.
System for analyzing the granulometric composition of material,
controlling oversize, foreign objects and material volume on a conveyor without waiting for a laboratory sample.
Sample-based control and visual assessment give a delayed picture. Production continues to operate in a non-optimal mode while the actual flow quality has already changed.
The crushing mode decision is made after the material flow has already changed.
Result: equipment works blindly.Large pieces and foreign objects increase the risk of blockage, damage and unplanned stops.
Result: crusher downtime risk increases.Excessive crushing increases energy consumption, liner wear and productivity losses.
Result: higher cost for the same volume.Without an archive of frames and events, it is difficult to identify causes of deviations by shifts, batches and modes.
Result: decisions are made by feel.Algorithms continuously analyze video frames and perform granulometric composition analysis, calculate fraction distribution, detect oversize and foreign objects, determine material volume per unit of time and record flow dynamics.
Results go to the operator and technologist interface, are stored in the archive, used in reports and sent to enterprise systems — SCADA, MES, ERP, BI or other systems via API and industrial protocols.
Continuous real-time analysis: from checking material presence and camera status to fraction analysis, oversize detection and control signals.
Share of fine, medium and coarse fractions in the flow.
Events that can lead to an accident, blockage or stop.
Factors that affect process stability and measurement quality.
The operator sees alarms and the current picture, the technologist sees distributions and trends, and management sees KPIs by shifts, lines and objects.
The solution includes not only algorithms, but also an industrial control point: camera, protective housing, lighting, optics cleaning, computing contour and integration into enterprise systems.
The device includes a machine vision camera with a lens and automatic focus adjustment module, an industrial computing unit, power and temperature control modules, a protective enclosure, and an air-blow and automatic optics cleaning unit. The system is designed for dust, vibration, complex lighting and local data processing requirements. Focus, zoom, exposure and working area can be configured remotely without opening the protective enclosure.
The industrial camera is installed above the conveyor with dust, vibration, maintenance access and measurement stability taken into account.
Focus, zoom, exposure and working area are configured remotely without opening the protective enclosure or extra site visits.
Data can be processed at the customer's site: edge, local server or hybrid scheme, without external transfer.
The system integrates with any enterprise internal systems via API, databases and industrial protocols.
The system is compared with the customer's reference method: sieve analysis, laboratory data, manual annotation or an approved acceptance program. Final indicators are recorded in the test protocol.
Accuracy depends on material, lighting, layer height, camera angle, reference sample quality and operating conditions.
STATANLY projects are related to granulometric composition analysis, industrial images, material structure and control of technological deviations.
Computer vision algorithms were developed to detect rocks on the belt, track objects in the video stream and build a size distribution.
The system is intended to automate granulometric composition assessment and support mill control based on data from a camera above the conveyor.
A software and hardware complex was developed for real-time analysis of ore granulometric composition.
The system determines fraction distribution, detects oversize and foreign objects, sends measurement results to industrial control systems and generates control signals to change the crusher discharge gap via Modbus.
A system was developed for operational analysis of gypsum mass porization and comparison of a sample with a reference image from a camera or microscope.
An additional foam-generation control scenario was developed: evaluating foam characteristics and sending an operator signal when deviations occur.
We will select the control point, reference method, set of indicators and pilot format for your line, material and production process.
We start with a measurable pilot, confirm the effect, then extend the solution to lines, areas and adjacent scenarios.
1–3 days: control point, material, camera, lighting, dust, vibration, reference.
1–2 weeks: video stream, server, network, working zone and initial calibration.
2–6 weeks: algorithms, events, thresholds, interface, archive and reports.
1–2 months: comparison with reference, test protocol and effect assessment.
New lines, cameras, materials, fractions and adjacent control modules.
We will select pilot scope, equipment, acceptance metrics and comparison format with your reference method.
The software is included in the Russian software registry. Below are details on system purpose, rights holder, functional characteristics and documents.
Name: System for analyzing group process-significant characteristics of objects densely located in an image.
Purpose: analysis of homogeneous grouped objects, granulometric composition analysis, detection of foreign objects, determination of ore volume on a conveyor, defects, oversize and camera data.
Country of registration: Russia
Legal form: Limited liability company
OGRN: 1237800072982
INN: 7801724456
General Director: Sergey Olegovich Fedorov
License: OEM, FullPackageProduct, VolumeLicensing, Subscription
