AUTOMATION &
C O N T R O L S
C ollisions between items of moving plant, such as a stacker and reclaimer, are difficult to anticipate and
prevent. The resultant damage to the plant as well as lost production can be significant.
Wireless anti-collision system
The traditional methods of collision
detection are either based on linear
transducers, shaft encoders or infra-red/
radar distance detection systems. The
linear transducers and shaft encoders tend
to “slip” and must be zeroed from time to
time. Maintenance of these systems is also
very high. The infrared/radar systems must
be kept immaculately clean at all times
for proper operation. This is very hard to
ensure in yards with fine powdery material
such as coal, iron ore, etc.
Neither of the systems mentioned above
can be considered as “fail-safe”. In
applications where the mobile plant
operates without being confined to rails,
such as straddle cars in ports, the collision-
detection technologies mentioned are
totally inappropriate. These deficiencies arefixed obstacle, the position determination
Fig. 1. A stacker/reclaimer set.
Fig. 2: Free moving mobile plant.
Information from Prodesign
addressed with the wireless anti-collision is settable by the user. The accuracy of the
system described below. The wireless computed, relative distances between the
anti-collision anticipation and prevention machines is <10 m. This anti-collision
system is based on a precision global detection system has no moving parts and
positioning system (GPS) determination thereby requires minimal maintenance.
of the various items of plant. These The radio antennae must be cleaned
positions are constantly fed to a central from time to time. The system is entirely
position determination computer system failsafe and will not allow the plant to
that continuously computes the relative operate if there is a failure or system
positions of the various items. error in the wireless anti-collision system’s
If an impending collision is detected position determination computer.
through two machines approaching within System diagnostics are available on a
a predetermined distance from each other,
data port on the position determination
or a mobile item approaching a known computer that can be accessed with a
laptop PC. If the mobile machines do not
c o m p u t e r have centrally located circuit breakers
immediately that can be tripped then the wireless anti-
provides an output collision system can be extended so that
that can firstly be the alarm and trip signals can be delivered
used to sound an to the specific pieces of plant by means of
alarm followed by a very secure radio signal that will comply
a trip signal to the with all legal requirements.
offending pieces
of plant and/or Fig. 2 shows free moving mobile plant,
its programmable such as straddle cars moving between fixed
logic controller obstacles, presenting multiple collision
(PLC). opportunities. The fixed obstacles must be
identified and their locations stored in the
Fig. 1 shows a wireless anti-collision system’s position
stacker/reclaimer
determination computer.
set that during
normal operation Where fixed obstacles must be
can possibly recognised, high accuracy differential
collide as a result GPS signal processing is used to provide
of operator error. positional accuracy for both the moving
The stacker and as well as fixed objects of < 1 m.
reclaimer shown H i g h i n t e g r i t y, e r r o r- f r e e d a t a
has trailing control communication between the central
cables between control system and the mobile machines
the moving plant
are provided by radio systems employing
and the central
PLC. The distance “stealth” technology developed during
between the units the Cold War.
that will sound an
alarm, as well as
the distance that
will cause a trip, Continued on page 47 ...
June 2007 - Vector - Page 44
... Continued from page 44
The data communication can be direct
communication between the central
position determination computer and
the PLC or other control systems on
the straddle cars. Alarm lights and
or audio signaling devices are also
used. The exact time and date of every
potential collision occurrence and
resultant alarm/trip can be archived for
subsequent, post-event investigation.
Shown alongside are two integral radio
transceivers, antennae and media
converters mounted on the spindle of
an ash stacker and connected to the
June 2007 - Vector - Page 47
control system with rugged polymer fibre
optic cables routed along the existing
cable festoon.
Contact Lore Holtzhausen, Prodesign,
Tel 011 314-2510,
lore@prodesign.co.za ∆