Optimization of Bulk Handling Control System using Sensor Force Feedback

Eric Veikle, Lead Solutions Engineer at Altair presents at the 2024 ATCx DEM.

In bulk handling systems, precise motion control is crucial for optimizing material transport and system efficiency. This presentation introduces a method for optimizing these systems using sensor force feedback through co-simulation with Altair EDEM and Altair MotionSolve. Force-based sensors, like load cells, detect material presence and control system components. Traditional methods rely on physical prototypes, leading to costly design changes.

This virtual simulation approach integrates Discrete Element Method (DEM) with multi-body dynamics (MBD) to optimize system performance before fabrication. For example, the motion of an inclined auger is controlled by real-time forces from bulk material on sensors, allowing early-stage design improvements. The method dynamically adjusts auger speed based on sensor feedback and can be further enhanced with tools like Altair HyperStudy and Altair Twin Activate. This approach offers a flexible, cost-effective solution for optimized motion control in complex bulk handling systems.