Our online systems will allow you to monitor a wide variety of material. From Pit to Plant, our systems can measure particle size, shape, volume and colour on conveyor belts and particle size, shape and colour on LHD, HD or railcar vehicles in real-time.
Momentum 5 systems are designed to accept up to 6 camera locations on a single workstation giving a complete picture of fragmentation. Examples of different configurations include combinations of conveyor and vehicle camera assemblies. For example: one Momentum 5 base system can have six conveyor cameras, three regular conveyor cameras plus one vehicle camera or two vehicle cameras.
Our Solo Online Conveyor Particle Analysis Instrument is a compact, portable, all-in-one design. It can be rapidly deployed and remotely accessed from anywhere.
Reflex is an automated real-time fragmentation analysis NEMA 4/IP 66 rated instrument designed to measure particle fragmentation/blast material on moving LH or LHD vehicles at the primary crusher without disrupting production. It has laser triggering capabilities to sense the location of the truck before capturing images, a built-in solid-state workstation and industrial grade camera. This technology operates autonomously, 24-7 and the results can be viewed on your iOS, Android or Windows device.
Our Vertex Online Targeted Particle Detection Instrument is specifically designed for these applications. It is a compact system that can be installed on virtually any size conveyor belt. It is very user-friendly, small and economical.
Vertex S is a purpose-built system that detects oversize material allowing automation and improved crusher output optimization efforts.
Vertex C is one of our newer online systems that is specifically designed to detect colour of rock/ore on a conveyor belt system in real time. The onboard colour camera allows the unit to detect and highlight the two (2) colours of interest and has the ability to send signals to an alarm/PLC/event process.
Momentum 5 can be calibrated. The process does take some time and requires multiple analyses and sieve samples. When our Technical Specialists come on-site to commission a new system installation, they will calibrate your system. If you need to do additional calibrations after installation, at a later date, then here are the steps to follow:
Stop belt with the material present. Manually capture an image with Momentum, analyze the image and save results. Remove the section of material from the belt (that was in the image) and sieve. Repeat this procedure at least 5 times to get adequate representation of the material. Email all of the results to firstname.lastname@example.org.
We will use our calibration tools to get a Rosin-Rammler or Swebrec calibration target and email you back the figures. You can then set these values by connecting to the system using WipFrag 3.
These ranges affect the minimum and maximum allowed shutter speed for the camera. However, these values are not represented in any units of time. Unfortunately, these ranges for the shutter speed cannot be easily converted to milliseconds (the conversion changes depending on many factors). Therefore, you will need to use trial and error by increasing/decreasing the values and taking note of the resulting shutter speeds displayed directly above these range values. To try and further explain, below is an example of its behaviour. However, the below numbers are NOT necessarily correct and are used only for demonstration.
Let’s say a system has the shutter limits set to 10-100. You introduce a lot of light and find the shutter never goes below 0.3ms (while the image remains too bright), then 10=0.3ms. You take away light and the shutter never goes above 3ms (while the image remains too dark), then 100=3ms.
However, the entire shutter range of the camera cannot be expressed with a linear equation and you will probably find that solving for values outside of this range will be incorrect. For example, you may expect 1=0.03ms, but you should expect to find that this is incorrect once you actually enter these values into the software.
Reflex cannot be accurately calibrated. The Reflex system is installed at a stationary location and the camera is pointed at an area where material is being unloaded. An advanced sensor on the system triggers the camera at the moment it unloads to ensure an ideal photo for analysis.
Our current generation of online systems can output volumetric data if provided with other information (specific gravity and a static or dynamic belt speed). The output values include volume, daily volume, volume rate, mass, daily mass, mass rate. With drones, WipFrag works with orthomosaic images and so the same image cannot provide volumetric data.
The online systems generate daily logfiles which contain every data point captured and yearly logfiles which contain hourly average entries for each day. The systems can be configured to automatically send daily emails with the daily logfile and a daily summary report attached. You can also gather daily information from daily drone flight images.
Note to online system users:
Please remember that if you change the zoom on your cameras or alter the lighting, you will most likely need to reset your EDP. Take 20-30 images over a day and find an EDP that works well on all of them. Recheck the EDP after 1 week to verify it is still working well. EDPs should not be altered during studies, projects, etc. Unlike scaling errors, EDP mistakes cannot be corrected for when post-processing the data. EDPs will not work perfectly for all images. A few small fusion and disintegration errors are common in all photo analysis software.
The user should take special care not to inadvertently bias the sample by altering the method in which image samples are taken, setting the scale improperly, selectively editing the net or changing the EDP between samples that will be merged to each other. All analysis of a study should be performed in the same way. Be systematic and develop a routine for image acquisition and analysis.
Please refer to section 3.0 of the Sampling and Analysis Guide for more information.
WipFrag 3 laptop requirements: Windows 10 (64 bit) OS with a 1.5 – 2.5 GHz Processor and at least 4 GB of memory is ideal.
WipFrag for Windows software keys support network license sharing. The license is attached to the hardware of one computer and can be shared across a company’s local network. Only one computer at a time can use the license.
WipFrag hardware keys do not have network license sharing, however it can be moved from computer to computer because the license is contained on the USB-type license key.
WipFrag 3 is available as an app on the App Store or Google Play. If you wish to download the app, click here.
All iOS and Android licenses are tied to your Apple or Gmail ID. You can have up to 10 devices connected to any single Apple or Android ID. If more devices are needed, you would need to purchase another license or remove devices to free space.
Newly created Apple IDs should wait 24 hours before purchasing WipFrag 3 from the App Store. Making a large purchase immediately after creating a new account highly increases the chance that your purchase will be blocked (for your protection) and your account will become flagged. Contacting Apple directly is the only way to resolve this issue if it happens. You can find a list of Apple support phone numbers at https://support.apple.com/en-us/HT201232
WipWare recommends using any solid scaling device with a contrasting colour to the material which can be laid down flat onto the material in question. Range rods, yard/meter sticks and customized frames can all be used. WipWare discourages the use of balls as they can expand and contract with changes in temperature and altitude. Be sure to have the scaling device perpendicular to the camera. Be sure to use two scaling devices when you cannot be parallel to the sample. This will allow you to use the tilt-correction within the software for more accurate results. If in doubt, use two scales. One in the foreground of the sample and one in the background.
It is recommended to avoid acquiring images early in the morning or late in the day when the sun is at a low point. It is during these times that long shadows are created around the particles (especially oversize) making it harder to find an adequate edge detection parameter. From our experience, when taking pictures outside, ensure you take images when the sun is neither directly overhead nor very low in the sky. The most ideal images are taking late morning or early afternoon on overcast days. Lighting is usually very even during these times creating a slight shadow around all particles. This makes finding an EDP very easy and greatly reduces editing times.
When taking images underground, our edge detection algorithm, which allows the software to determine the edges of all the particles, relies on strong shadows around the edge of the particles. A simple way to do this is by providing a light source from two directions, about 45 degrees to the material.
The number of images needed to properly analyze muckpiles or another sample is dependant on a number of things and changes from project to project. The main question to ask yourself when you think you are done obtaining your images is “did I gather an adequate statistical representation of the material in question?”. If you have missed the smaller particles, or feel that perhaps they were too small to be delineated, you should take a few zoomed in images of them. As well, if you have neglected the oversize material, you may need an image of them as well. Remember, you can merge multiple analyses together within the software very easily.
If you see a great deal of fines when acquiring the images, capture some zoomed in images of the material. WipFrag’s ability to merge analyses will allow you to incorporate these fines into your overall study. When analyzing images containing material that cannot be delineated, you can choose to mark areas as fines using the ‘Mark as Fines’ edit tool. These areas will be treated as material that is the size of 1 pixel based on the current scale factor of the image.
If you wish to resolve smaller particles, there are two options. You can choose to use a higher zoom lens. Zooming in allows the system to resolve the smaller particles much easier. It can, however, reduce the number of the larger particles analyzed. The other option is to update your camera. New camera technology has allowed us to greatly increase the minimum resolvable particle size within images and still keep the larger particles within the results. By moving from the standard 0.3Mp camera to one of our 2.1 or 10.7Mp options, you can increase your resolved particle magnitude from 43x to 267x. Simply put, your system will be able to analyze particles up to 1/8th the size of the smallest particle that your system is measuring now.
Digital zooming reduces the definition in your images. When you choose to digitally zoom, your camera is actually cropping and expanding the image. This effect makes it appear as if the image has been zoomed in. The problem is, when the camera expands the image, it needs to interpolate pixels which reduces the clarity and definition of your photo. Wide angle lenses should be avoided as well. In order to obtain a wide format image, distortion is created at the edges of the photo. The wider the lens, the more distortion there is.
Large and small images each have their pros and cons. Fines can be delineated easier with larger images and tend to get fused together with smaller images. Oversize is usually analyzed properly with smaller images but tends to get slightly disintegrated in larger images. Smaller images analyze and are edited much faster than large images. WipWare always recommends taking the original images at a high resolution. It is always possible to downsize the image without distortion, but nearly impossible to make an image larger while keeping clarity and definition. As a rule of thumb, if you cannot delineate the particle with your eye, the software will be unable to as well.
- Good quality camera (>6 megapixels still images)
- Good flight time (>25 minutes is suitable for most applications)
- Gimbal capable of downward view (perpendicular to the ground)
- Capable of iOS interface for autonomous mission planning & flight
- Good flight speed (>40mph/65kph necessary for wind resistance)
- Good operating range (>4mi/6.4km helps in pit environment)
- Automatic collision avoidance and return to home capability
- Reasonably priced and easy to find parts/accessories
- GPS & GLONASS
When acquiring image samples each image should:
- Contain an easy to read scale (two for tilt correction)
- Be high definition – not necessarily high resolution
- Never be taken with a wide angle lens
- Contain clearly visible particles (if you can outline each individual particle, the software can too).
- Have even lighting (avoid hot spot/shadow areas if possible).
The most important thing about photoanalysis software is the quality of images that are used for the analysis. Image Acquisition – The better the images, the better the results. Develop a sampling strategy. Taking images is like taking samples for sieving or other tests. The results must statistically represent the product as a whole. To adequately compensate for rockpile segregation and heterogeneity, each image must contain a sufficient number of fragments, and the results from dozens of images per blast must be merged and averaged. Accurate estimation of larger blocks in particular requires merged data because of the scarcity of such blocks. High-fidelity, high-speed automatic edge detection is essential – methods that rely on tracing or manual editing are incapable of processing sufficient data and so are prone to large sampling errors.
- Fill the field of view with fragmented rock, preferably at least 200 particles.
- Include all sizes. No single block should occupy more than 20% of the width of the image. For improved resolution of fines, use WipFrag’s zoom-merge capability to combine images at different scales of magnification.
- Beware of rockpile segregation. Large blocks tend to roll to the outer edges and fines may cover the surface or become hidden as a result of gravity or rainfall. The effects can be minimized by increasing the number of images per sample but only with careful selection of image locations.
- Don’t waste an image. Get images of the particles in question, not the sky and area around it.
- WipFrag measures what it can see. If your pictures are far away, fines will not be resolved. If the image is taken too close, oversize may be missed. Get a good mix of images of the sample in question.
For more information please read the Sampling and Analysis Guide
Lost license keys cannot be replaced. WipWare recommends that the license key is insured for the replacement value of the software product to protect against loss or theft. Damaged license keys can be exchanged for a nominal cost. Keys that have been damaged due to tampering may be replaced at the discretion of WipWare.