Stuart Jack & Hamish Cameron Fusion ERP - …

1 2006 - SEPS tockpile Volume CalculationIn conjunction withSupplied by Stuart jack & Hamish Cameron Fusion ERP ..any sufficiently advanced technology is indistinguishable from magic. Arthur C. ClarkFRAME WORK OF PRESENTATIONINTRODUCTIONPOWER POINTDEMOS:Volumetric calculation of a stockpileInputs (rail trucks and trailers)Outputs (conveyors & containers)OtherDISCUSSION / QUESTIONSD igital System, recordReal time monitoringLayout of stockpilesPREDICT AND ALARM Automatic systems, no human involvementCCTV / IPDecreased costs, improved performance Why do Image Analysis?!Better Definition of Contrasting Areas!

2 Improved Precision/Accuracy in Measurements!Reproducibility of Results!Higher Throughput than Manual MethodsA Word About Our Eyes!Eyes are very good contrast adjusters, but not good for distinguishing subtle variations in color!Eyes can discern about 30 continuous levels of gray or color in a field of view!Eyes are not good judges of distance!Eyes cannot accurately reproduce measurementsWhich is BIGGER / LONGER???IMAGING DEVICE (X NO OF CAMERAS)Frame Grabber / IPIAS oftwarePC StationSYSTEM CONFIGURATIONSYSTEM CONFIGURATIONF usion ERPV isual / Audio SMS / E-Mail AlarmsElectronic Imaging FundamentalsAcquireProcessIdentify AnalyzeReportArguably, the most important aspect of all!

3 Proper setup of imaging apparatus is vital !Obtain maximum contrast and dynamic range!Reduce noise and other unwanted artifactsAcquiring the ImageReporting DataExport to 3rd PartyExport to 3rd Party All data available viaFusion ERPN eural networksOperate in real time; utilised extensively world wide. Based on neural networks, I-CUBE software delivers cutting-edge security and split-second processing ability to automatically predict and identify those involved in wrongful unitisation of resources greatly empowers traditional Holland Hungary Litha Italy IsraelChinaHong KongKoreaTaiwanThailandSingaporeArgentin a South Africa Australia Camera OPTIONS The traditional means of connecting cameras in machine vision (and other similar applications)

4 Is through a dedicated frame grabber/ image acquisition board installed in a Several computer industry based interfaces, such as Ethernet, USB and FireWire have been early candidates for serving as a digital serial camera interface. Shortcomings in transmission speed, transmission efficiency and standardization ruled these candidates out for many years, and the industry has continued to use frame grabber based of different interfacesLowLowHighLowLowCPU LoadPCI Frame grabber1<10mRepeater is possible100 s of meters<2380Mb/s (base) <7140Mb/s (full) continuous modePoint to point link (MDR 26 pin)CommercialCamera LinkPCI Frame grabberOn mother boardPCI cardGigE NIC (on mother board)PC InterfaceDepends on MUX12763 UnlimitedMax number of devices:100 s of meters<5m30m< <100m (no switch)No LimitNo LimitDistance.

5 -max w/switch-max w/fiberDepends on digitization in Frame Grabber<480Mb/s USB2 burst mode<800Mb/s continuous mode, equivalent to 65 Mbytes/sec<1000Mb/s continuous mode, equivalent to 100 Mbytes/secPerformance:Point to point/multiplexedMaster/slave shared busPeer to peer shared busPoint to point or LAN link (Cat 5 TP -RJ45)Connection Type:Commercial /BroadcastConsumer/ OfficeConsumer/ Computer NetworkCommercialType of standard:Analogue Coax or Twisted PairUSB2 IIDC IEEE 1394 BGigE VisionTechnology:Adapting Gigabit Ethernet for Vision Gigabit Ethernet in itself provides 10 times higher bandwidth than 100 BaseT ethernet, However, the inherent overhead of Ethernet for computer networksusing standard TCP/IP Windows stack makes it less attractive fordemanding applications due to: Small packets High CPU usage By adopting a modified protocol [based on UDP] with jumbo packetsandby implementing a high performance driverreducing CPU usage to a few percent, an attractive solution is created.

6 This standard is named GigE Gigabit Ethernet for VisionStandard packet: 1440 Bytes (56 Bytes header) Jumbo packet: Max. 16224 Bytes (one 56 Bytes header) efficiency*99,7% efficiency*In combination with a High Performance Driver, based on TCP/IP offload-engine, it provides higher transmission efficiency and drastically reduces CPU usage.(High CPU overhead for sending many small packets)(Very low CPU overhead as only one packet)*) Comparison based on sending 16224 bytes of dataFrame Grabber-free solutionLensImage sensorDigitizingPre-processingTimingInte rfacePLCCat-5eEthernet cableup to 100 mLocal I/Os.

7 -Trigger input-Results outputIllumination controlImage ProcessinginPCIllumination(Lens IrisVideo)PowerExample showing Gigabit Ethernet camera interface, with additional functionality100110001010001110001010011 100100100011101100011001010001000 PCPCP ossible system configurationsPoint-to-point(One camera, one PC)GigESwitchMany-to-one(Multiple cameras, one PC)One-to-many (broadcast)(One or several cameras, with several PCs)GigE cameras for Vision TM(C)-6740GE 640 x 480 pixels 1/3 format 200 frames / sec. TM(C)-4100GE 2048 x 2048 pixels format 15 frames/sec. TM(C)-1405GE 1392 x 1040 pixels 1/2 format 30 frames/sec.

8 Smaller cameras Higher performance Cost reduction Monochrome and color Extensive pre-processing capability Higher interface speed (10 GigE) Resolution ranging from VGA to megapixel Ease of implementationRequirement: Requirement: To provide OPTICAL To provide OPTICAL technology to calculate stockpile technology to calculate stockpile volume measurements. volume measurements. MONITORING & REPORTING of all MONITORING & REPORTING of all INPUTS and OUTPUTS, the weight of:INPUTS and OUTPUTS, the weight of:--Trucks, containersTrucks, containers--Trains, Conveyors etc. Trains, Conveyors etc.

9 Volume CalculationConventional methods of surveying are over-shadowed when it comes to volume calculations. These following examples show the speed and accuracy of this method, and highlight how safety is an important issue. Volumes of stockpiles can be accurately and rapidly measured. Volume Calculation Case StudiesImproving ProductivityAs companies employ total quality management methods to increase their competitive advantage, accurate volume measurement is becoming vital. This method delivers reliable results for reconciliation and contractor payments. Anore stockpile in North America.

10 Volume Calculation Case StudiesStockpiles for varying resources have been scanned:- Ore stockpiles in the Hamersley Iron port facilities- Mill stockpiles at PT Freeport Grasberg site - Coal stockpiles at the Wesfarmers Coal site - Multiple product stockpiles at the Penrice Soda Products chemical grade limestone mineThe results far exceed the speed and accuracy of conventional methodsVolume Calculation Case StudiesVolume studies on haulage vehicles including trucks, trains, shovels or draglines. Accurate measurements can help resolve reconciliation issues, with minimal interruption to normal production.