Real-world model based validation of blending bed simulation techniques

Existing research claims highly detailed simulation of stockpile buildup and reclaiming processes in blending beds based on sophisticated physics simulation. Optimization mechanisms integrating these simulations allow significant improvement over standard homogenization techniques using existing machines by adding real-time quality measurement and software-based stacker control. The effect of the optimization system on the homogenization however is evaluated within the proposed simulation system itself, which, although based on real-world physics and simulated bulk material, has not been validated with measurements on actual physical matter yet. In this paper the simplifications are discussed which need to be made to physics simulation in order to be applicable in optimization systems and their implications on simulation quality and degree of realism. In order to validate the actual degree of realism in simulation systems the young engineer team of J&C Bachmann built a functional real-world model of a stacking and reclaiming system using inexpensive materials and their creativity, crafting and implementation capabilities. For the first time this flexible and highly detailed real-world validation system for bulk material blending systems is available and utilized to evaluate existing simulation approaches.