Controllers and methods for bulk explosive loading systems

Abstract

Controllers and methods of bulk explosive loading systems are disclosed. A controller of a bulk explosive loading system includes a communication interface configured to communicate with a human-machine interface (HMI). The HMI is configured to execute a software program configured to enable the HMI to receive user inputs from a user. The controller also includes control outputs to output control signals to electrically controllable components. The controller further includes sensor inputs configured to receive sensor signals from sensors configured to monitor the bulk explosive loading system. The controller also includes a processor configured to process recipe information received from the HMI, generate the control signals based on the recipe information to control the electrically controllable components to blend the mixture, process the sensor signals received during blending of the mixture, and transmit blending information to the HMI device. The blending information includes information regarding the blending of the mixture.

1 - 20 . (canceled) 
     
     
         21 . A mobile bulk explosive loading system, comprising:
 electrically controllable components configured to mix and deliver an explosive mixture to a blast site;   a controller operably coupled to the electrically controllable components, the controller configured to control the electrically controllable components to mix and deliver the explosive mixture according to recipe information and delivery information;   a human-machine interface (HMI) device comprising:
 a processor; and 
 a data storage device to store computer-readable instructions configured to instruct the processor to:
 present, on an electronic display of the HMI device, a graphical user interface (GUI), the GUI including user inputs for parameters of an explosive delivery; 
 transform the parameters of the user inputs to instructions for the controller to follow when blending and delivering the explosive; 
 store, on the data storage device, the instructions for the controller as the recipe information and the delivery information; and 
 
   a communication interface configured to enable bi-directional communication between the HMI device and the controller, the communication interface configured to deliver the recipe information and the delivery information generated by the HMI device to the controller to enable the controller to control the electrically controllable components according to the recipe information and the delivery information.   
     
     
         22 . The mobile bulk explosive loading system of  claim 21 , wherein to transform the parameters of the user inputs, the HMI device determines one or more of a delivery rate, an amount of a PH control agent to add to an emulsion explosive, and an amount of a chemical gassing agent to add to the emulsion explosive to achieve a desired density. 
     
     
         23 . The mobile bulk explosive loading system of  claim 21 , further comprising one or more sensors operably coupled to the controller, the one or more sensors including at least a temperature sensor configured to measure a temperature of an emulsion matrix, wherein the controller is configured to transmit temperature information received from the temperature sensor to the HMI device through the communication interface to enable the HMI device to determine proper amounts of one or more gassing agents to add to the emulsion explosive to achieve a desired density of the emulsion explosive. 
     
     
         24 . The mobile bulk explosive loading system of  claim 21 , wherein the software application is further configured to instruct the HMI device to:
 receive operator credentials;   determine a security level associated with the operator credentials; and   reconfigure the HMI device to provide access to inputs associated with a minimum authority level that is equivalent to or less than the security level associated with the operator credentials.   
     
     
         25 . The mobile bulk explosive loading system of  claim 21 , further comprising a global positioning system (GPS), wherein the HMI device is further to:
 track an amount of the explosive mixture used to fill a borehole;   associate a coordinate from the GPS with the amount; and   provide a delivery log of the amount of explosive mixture at the coordinate.   
     
     
         26 . The mobile bulk explosive loading system of  claim 21 , wherein the HMI device uses a lookup table to transform the parameters of the user inputs to instructions for the controller. 
     
     
         27 . The mobile bulk explosive loading system of  claim 21 , wherein the controller transits blending information via the communication interface to the HMI device, the blending information comprising pumping pressures, ingredient delivery rates, or combinations thereof, and
 wherein the HMI device compiles the blending information, generates a report based on the blending information, and exports the report.   
     
     
         28 . A method for bulk explosive loading, the method comprising:
 presenting, on an electronic display of a human-machine interface (HMI) device a graphical user interface (GUI), the GUI including user inputs for parameters of an explosive delivery;   transforming, at the HMI device, the parameters of the user inputs to instructions for a controller to follow when blending and delivering the explosive;   storing, on a data storage device of the HMI device, the instructions for the controller as recipe information and delivery information;   sending, via a communication interface, the recipe information and the delivery information from the HMI device to the controller; and   controlling, via the controller, electrically controllable components to mix and deliver the explosive mixture according to recipe information and delivery information generated by the HMI device.   
     
     
         29 . The method of  claim 28 , wherein to transforming the parameters of the user inputs comprises determining one or more of a delivery rate, an amount of a PH control agent to add to an emulsion explosive, and an amount of a chemical gassing agent to add to the emulsion explosive to achieve a desired density. 
     
     
         30 . The method of  claim 28 , further comprising receiving measurements from one or more sensors operably coupled to the controller, the one or more sensors including at least a temperature sensor configured to measure a temperature of an emulsion matrix, and
 transmitting temperature information received from the temperature sensor to the HMI device through the communication interface to enable the HMI device to determine proper amounts of one or more gassing agents to add to the emulsion explosive to achieve a desired density of the emulsion explosive.   
     
     
         31 . The method of  claim 28 , further comprising
 receiving operator credentials;   determining a security level associated with the operator credentials; and   reconfiguring the HMI device to provide access to inputs associated with a minimum authority level that is equivalent to or less than the security level associated with the operator credentials.   
     
     
         32 . The method of  claim 28 , further comprising
 tracking an amount of the explosive mixture used to fill a borehole;   associating a coordinate from a global positioning system (GPS) with the amount; and   providing a delivery log of the amount of explosive mixture at the coordinate.   
     
     
         33 . The method of  claim 28 , wherein the controller mixes and delivers the explosive mixture independent of the HMI device. 
     
     
         34 . The method of  claim 28 , transiting, from the controller, blending information via the communication interface to the HMI device, the blending information comprising pumping pressures, ingredient delivery rates, or combinations thereof, and
 compiling, via the HMI device, the blending information, generates a report based on the blending information, and exports the report.   
     
     
         35 . A mobile bulk explosive loading system, comprising:
 electrically controllable components configured to mix and deliver an explosive mixture to a blast site;   a controller operably coupled to the electrically controllable components, the controller configured to control the electrically controllable components to mix and deliver the explosive mixture according to recipe information and delivery information;   a human-machine interface (HMI) device comprising:
 a processor; and 
 a data storage device to store computer-readable instructions configured to instruct the processor to:
 present, on an electronic display of the HMI device, a graphical user interface (GUI), the GUI including user inputs for parameters of an explosive delivery; 
 transform the parameters of the user inputs to instructions for the controller to use when blending and delivering the explosive; 
 store, on the data storage device, the instructions for the controller as the recipe information and the delivery information; and 
 send the recipe information and the delivery information to the controller to enable the controller to control the electrically controllable components according to the recipe information and the delivery information. 
 
   
     
     
         36 . The mobile bulk explosive loading system of  claim 35 , wherein to transform the parameters of the user inputs, the HMI device determines one or more of a delivery rate, an amount of a PH control agent to add to an emulsion explosive, and an amount of a chemical gassing agent to add to the emulsion explosive to achieve a desired density. 
     
     
         37 . The mobile bulk explosive loading system of  claim 35 , further comprising one or more sensors operably coupled to the controller, the one or more sensors including at least a temperature sensor configured to measure a temperature of an emulsion matrix, wherein the controller is configured to transmit temperature information received from the temperature sensor to the HMI device to enable the HMI device to determine proper amounts of one or more gassing agents to add to the emulsion explosive to achieve a desired density of the emulsion explosive. 
     
     
         38 . The mobile bulk explosive loading system of  claim 35 , wherein the software application is further configured to instruct the HMI device to:
 receive operator credentials;   determine a security level associated with the operator credentials; and   reconfigure the HMI device to provide access to inputs associated with a minimum authority level that is equivalent to or less than the security level associated with the operator credentials.   
     
     
         39 . The mobile bulk explosive loading system of  claim 35 , further comprising a global positioning system (GPS), wherein the HMI device is further to:
 track an amount of the explosive mixture used to fill a borehole;   associate a coordinate from the GPS with the amount; and   provide a delivery log of the amount of explosive mixture at the coordinate.   
     
     
         40 . The mobile bulk explosive loading system of  claim 35 , wherein the controller transits blending information to the HMI device, the blending information comprising pumping pressures, ingredient delivery rates, or combinations thereof, and
 wherein the HMI device compiles the blending information, generates a report based on the blending information, and exports the report.