Heguang Cloud ore particle-size analytics toward zero-fault crushing production
Efficient, accurate, low-cost ore particle-size analytics for mining through intelligence and automation
Customer background: crushing-line pain in cement ore
— LiDAR + AI vision fusion to break crusher choke and surprise downtime
A leading domestic cement producer runs mine-to-mill as mine → crush → grind. In crushing, ore feeds the mill via belt, but two issues persisted:
- Hidden equipment loss: worn or failed crusher teeth let >80 mm rock through, jamming the mill—single events cost well over CNY 500k;
- Slow manual checks: two-hour spot samples meant ~47-minute average delay before anomalies were noticed.
HEGANG YUNCHANG ore sizing: LiDAR + AI for live particle control
For this line, HEGANG YUNCHANG deployed the intelligent ore particle monitoring system—a three-layer defense:
1. Crusher health watch
- High-rate LiDAR scans the burden surface at line speed with about ±3 mm class accuracy;
- AI tracks size distribution—P80 swings over 5% raise automatic tool-change advisories;
- PLC interlock can trim pressure when oversize is detected.
2. Mill feed gatekeeping
- Industrial camera at 200 fps covers the belt width with sub-60 ms anomaly cues;
- Multi-stage thresholds (e.g., <50 mm to mill) can trip pneumatic diverters;
- 3D contouring estimates equivalent diameter with low false positives.
3. End-to-end data fabric
- Edge boxes process streams under ~200 ms for closed-loop hints;
- Control-room twins show size heatmaps, equipment health, and throughput forecasts;
- History-driven blade change guidance—fault rate down materially in the pilot.
Outcomes: from firefighting to predictive control
After go-live, crushing gained a step-change:
- Crusher maintenance cost down ~30% with fewer blade-related trips;
- Production efficiency up ~25% with tighter size to spec and fewer downstream plugs;
- Manual inspection load down ~90% with remote monitoring.
"HEGANG YUNCHANG's system is like putting a CT scanner on the line—we can see the ore 'internals' in real time and anticipate when equipment might fail. We moved from reactive firefighting to predictive operations."
HEGANG YUNCHANG ore sizing: core strengths
- Industrial reliability: IP68-class mechanical design, −30°C to 70°C intent for dusty mines;
- Models trained on 300k+ ore images for lithology and lighting adaptation;
- Modular install targeting under 72 hours to first data, PLC/MES friendly.
Core value tags: #intelligentinspection #predictivemaintenance #zerofaultproduction #Industry40