{"id":479,"date":"2026-03-10T10:00:00","date_gmt":"2026-03-10T14:00:00","guid":{"rendered":"http:\/\/wipware.com\/?p=479"},"modified":"2026-03-10T10:02:54","modified_gmt":"2026-03-10T14:02:54","slug":"continuous-monitoring-through-photoanalysis","status":"publish","type":"post","link":"https:\/\/wipware.com\/de\/continuous-monitoring-through-photoanalysis\/","title":{"rendered":"Continuous Monitoring Through Photoanalysis"},"content":{"rendered":"

<\/path><\/svg><\/span><\/span>Estimated reading time: <\/span>4<\/span> Minuten<\/span><\/p>\n\n\n

Zuhause<\/a><\/span> \u00bb Continuous Monitoring Through Photoanalysis<\/span><\/span><\/div>\n\n\n

WipWare <\/a>has been in the image analysis business for over 30 years commercially. We\u2019ve seen a wide range of mining and aggregate sites, all with their unique challenges. One thing that stays consistent with every operation is the need to reduce particle sizes to ideal sizes for either the extraction of minerals, or for more practical uses (road building, etc.)<\/p>\n\n\n\n

Blasting, crushing and grinding material down to an optimal size is difficult to do. When you tie in trying to be efficient at the same time, production rates can fluctuate quite easily. It\u2019s very hard to track how well the \u2018rock breaking\u2019 is going.<\/p>\n\n\n\n

Warteschlangensiebung!<\/h2>\n\n\n\n

Manuelles Sieben gibt es schon seit Tausenden von Jahren. Heutzutage ist die Genauigkeit dieser Siebanalysemethoden beeindruckend: Band anhalten, Schnitt machen, Material ins Labor bringen, in die Siebmaschine geben und fertig! In wenigen Stunden hast du dein Ergebnis. Was w\u00e4re besser?<\/p>\n\n\n\n

Well, let\u2019s back it up a little and investigate. Manual sieve samples are very accurate for the sample itself. However, if you use manual sampling to track, say, relative changes, you are putting a lot of faith in that one belt cut of material representing hundreds\/thousands of tons of material.<\/p>\n\n\n\n

Manual Sieving vs Continuous Monitoring <\/h2>\n\n\n\n

You may notice why WipWare systems are really taking a hold in the mining and aggregate industries:<\/strong> No one will ever argue that a manually sieving a sample is not accurate; but here is a scenario I want you to consider:<\/p>\n\n\n\n

You take a sample of a 1-meter belt cut every shift for analysis. When the crusher supplier asks for the material size going into the secondary crusher, you hand him\/her the beautiful distribution curves with the data points in the Excel file. Based on the data, he\/she decides \u201cbased on your material size, you need this kind of crusher\/liner\/product\u201d.<\/p>\n\n\n\n

Do those manual samples accurately represent the hundreds or thousands of tons passing through your process? What if the sample you took happened to be finer than what was typical? Chances are, as granulometry guru Jack Eloranta, of Eloranta & Associates<\/a> calculates, misrepresentation could be possible.<\/p>\n\n\n\n

Take a look:<\/p>\n\n\n\n

Annehmen:<\/p>\n\n\n\n

400 TPH<\/p>\n\n\n\n

6 m\/s<\/p>\n\n\n\n

1 Meter Bandprobe pro Schicht<\/p>\n\n\n\n

Band bewegt sich 1 Meter in 0,17 Sekunden<\/p>\n\n\n\n

0,17 Sek. x 1 Std.\/3600 Sek. x 400 t\/Std. = .019 Tonnen <\/p>\n\n\n\n

0,019 t\/(8 x 400) t = 0,0000059<\/p>\n\n\n\n

Really, when you look at how representative a manual sample is, you are looking at 0.00059% of your conveyor material in this example.<\/p>\n\n\n\n

With a percentage like that, I\u2019ll take continuous, non-disruptive particle sizing any day.<\/p>\n\n\n\n

So let\u2019s summarize so far: Manual sieving accurately measures the sampled material but may not represent the material continuously running through your process.<\/p>\n\n\n\n

What\u2019s WipWare\u2019s role in all of this?<\/strong><\/h2>\n\n\n\n

Well, it\u2019s really a complementary thing. WipWare is the ying to sieving\u2019s yang, the Sunny to sieving\u2019s Cher\u2026I\u2019ll stop now.<\/p>\n\n\n\n

\"Rock<\/figure>\n\n\n\n

WipWare\u2019s systems offer continuous monitoring of material. That\u2019s right. 24\/7\/365 analysis of the most important part of the mining process; the whole reason billions upon billions of dollars are spent each year; the reason why mine and mill employees have a love\/hate relationship \u2013 the size of material! Manual sieve results can be tied into the WipWare data using Rosin-Rammler or Swebrec functions, covering both the quantity of data needed for accurate analysis, with the quality manual sample information.<\/p>\n\n\n\n

WipWare\u2019s systems offer continuous monitoring of material. That\u2019s right. 24\/7\/365 analysis of the most important part of the mining process; the whole reason billions upon billions of dollars are spent each year; the reason why mine and mill employees have a love\/hate relationship \u2013 the size of material! Manual sieve results can be tied into the WipWare data using Rosin-Rammler or Swebrec functions, covering both the quantity of data needed for accurate analysis, with the quality manual sample information.<\/p>","protected":false},"excerpt":{"rendered":"

WipWare has been in the image analysis business for over 30 years commercially. We\u2019ve seen a wide range of mining and aggregate sites, all with their unique challenges. One thing that stays consistent with every operation is the need to reduce particle sizes to ideal sizes for either the extraction of minerals, or for more […]<\/p>\n","protected":false},"author":6,"featured_media":8318,"comment_status":"closed","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"footnotes":""},"categories":[49,48],"tags":[],"class_list":["post-479","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-reflex","category-solo"],"acf":{"related_posts":[{"ID":9289,"post_author":"6","post_date":"2025-12-18 14:04:55","post_date_gmt":"2025-12-18 19:04:55","post_content":"\n

Fragmentation analysis is a critical driver of mine performance, profitability, and sustainability. Accurate measurement and control of rock fragmentation from drill and blast to crushing and milling directly influence throughput, energy consumption, equipment wear, and operating costs.<\/p>\n\n\n\n

WipWare\u2019s <\/strong><\/a>fragmentation analysis solutions use advanced image processing and AI-driven technologies to deliver high-quality, real-time particle size distribution (PSD) data. This enables mining operations to optimize processes across the entire value chain, from pit to plant, while maximizing life-of-mine value.<\/p>\n\n\n\n

\"Mine<\/figure>\n\n\n\n

End-to-End Fragmentation Analysis: From Drill to Mill<\/strong><\/h2>\n\n\n\n

WipWare provides a fully integrated fragmentation monitoring ecosystem, offering consistent, accurate PSD measurement at every stage of material handling. By connecting blasting performance with crushing and processing outcomes, operations gain unmatched visibility and control over their production system.<\/p>\n\n\n\n

Online Conveyor Belt Fragmentation Measurement \u2013 Solo 6<\/strong><\/h2>\n\n\n\n

Solo 6 delivers continuous, online particle size distribution analysis for conveyor belts across the comminution circuit, including:<\/p>\n\n\n\n