TRANSACTION ON CONTROL AND MECHANICAL SYSTEMS, VOL. 2, NO. 2, PP. 54-60, FEB., 2013.

Investigation of the Bucket Wheel Reclaimer's Cutting

Trajectory to Define Optimal Voxel Shape
Maung Thi Rein Myo 1, and Tien-Fu Lu 2,
Abstract: Australian mining industry generates more than
half of total national income and provides a lot of employment
opportunities. It is essential for ore producers to supply iron
ore with requested mineral composition to oversea steel
producers for quality reputation. Blending is commonly used
to compensate the short term fluctuations of ore. However, the
delay in processing assay while blending motivates researchers
to focus on improving reclaiming approaches. In recent
studies, stockpile is considered as a combination of volume
elements instead of treating as a single entity. However, voxel
profile has always been defined as a cubic shape without
taking into account the reclaiming pattern of the bucket wheel
reclaimer (BWR). The objective of this paper is to investigate
drawbacks of using cubic voxels in reclaiming with BWR. A
kinematics model of the BWR including its bucket wheel is
derived. Using the derived kinematics model, the cutting
trajectory of the BWR is simulated to illustrate the potential
voxel profile for future study.

lump and fines. A flow of ore from mine sites to ship is

shown in Figure 1. Blending is carried out at the port using
stackers and BWR before loading onto ships. Crushing is
normally carried out at the port to prevent degrading of
lump to fines in railing which is less valuable [4]. After
crushing, lump and fines are assayed in the laboratory to
acquire mineral composition. A couple of hours delay in
processing assay enforce to stack ore using blending before
obtaining exact mineral composition [3]. It means the exact
mineral composition is available when it is reclaimed to
load onto ships. The available of mineral composition in
reclaiming motivates researchers to focus on improving
reclaiming approaches.

Keywords: Bucket wheel reclaimer (BWR), kinematics, voxel,

cutting trajectory
1

1. INTRODUCTION
The mining industry of Australia generates $138 billion
income per annum, which represents 54 % of total
Australian income. Besides it employs 187,400 people
directly, and a further 599,680 in support industries [1].
Among bulk materials, Australia plays leading role in
exporting iron ore in the world [1]. Iron ore is exported to
overseas customers to feed into blast furnaces for making
steel. Blast furnaces are finely tuned to accept only specific
mineral composition. Steel producers concern not only iron
composition as well as the composition of other
contaminates such as silica, alumina and phosphorous when
buying from ore producers [2]. Therefore, it is very much
concern for ore producers to supply the ore with required
mineral composition to maintain quality reputation.
Ore producers plan mines production over a year to
average a desired composition but the short term fluctuation
is inevitable [3]. To compensate the short term fluctuation,
blending is commonly used to achieve consistency in
mineral composition. Blending refers to combination of ore
from different blocks (pits, streams, etc.) onto a single
stockpile. The ore is excavated from open cut pits and railed
to the port. At the port, the ore is crushed and separated into

Fig. 1. A typical iron ore production system [2]

Besides, blending requires a lot of handling activities of

stackers to decrease the variation in grade composition. Ore
producers prefer less handling activities to reduce handling
costs while achieving grade uniformity [5]. The voxel based
approach was introduced by SimineCIS [6] and Lu & Myo [7-8]
in focusing on reclaiming material from the stockpile. In
which, stockpile is treated as a combination of volume
elements called voxels instead of considering as a single
volume. The details of the studies are discussed in the
literature review section.

2. LITERATURE REVIEW
To the best of authors knowledge, all previous studies
except three studies treated stockpiles as a single entity with
average quantity and grade. In this literature review, the
three most relevant studies are reviewed. The first study of
literature treating stockpile as a combination of unit volume
is conducted by SimineCIS. SimineCIS introduced a
comprehensive
material-monitoring
system
for
straightforward quality planning and material blending
called SimineCIS MAQ in 2009 [6].

1
Maung Thi Rein Myo, Department of Mechanical Engineering,
University of Adelaide (Email: maung.myo@adelaide.edu.au)
2
Tien-Fu Lu, Department of Mechanical Engineering, University of
Adelaide (Email: tien-fu.lu@adelaide.edu.au)

RECEIVED: 25, DEC., 2012; REVISED: 16, JAN., 2013; ACCEPTED: 18, JAN., 2013; PUBLISHED: 27, JAN., 2013.

ISSN: 2345-234X

REIN MYO et al.: INVESTIGATION OF THE BUCKET WHEEL RECLAIMER'S CUTTING TRAJECTORY TO DEFINE OPTIMAL VOXEL SHAPE.

In SimineCIS MAQ, the stockyard is divided into cubic

meter virtual grids in regard to quantity and quality as
shown in Figure 2. The quality data, quantity information
and a timestamp are stored in the material-data record and
updated each time the stockpile is changed. The updated
3-D and compressed 2-D model of the stockpiles is shown
on monitor for viewing of the operator. Based on the
stockpile view on screen, the operator selects the relevant
unit volume grids to meet the demand quantity and target
grade. The calculated resulting total grade and quantity
information is displayed before physically reclaimed from
the stockpile.

55

target falls within the demand range and thus the proposed
optimization satisfies the demand with the BWR minimum
movement.

Fig. 3. Stockpiles with cubic voxels form in SPSim [8]

Fig. 2. 3-D stockpile image [5]

For the purpose of dividing stockpile into voxels and

analyzing mineral distribution of the stockpile, a stockpile
simulator (SPSim) was developed by Lu and Xu in 2010 [9].
Voxel is defined as a volume element with custom defined
shape. The development of SPSim involves a simulation
engine and stockpile visualization component. An efficient
Cellular Automata (CA) model was used in the stockpile
simulation engine to simulate mineral grains motion and
predict their locations. In stockpile visualization, hybrid
approach consisting of shape-based volume approach and
texture-based height approach was utilized. The
texture-based height approach was used to express the heap
growth process and the shape-based volume approach for
the mineral grains dropping stage from the stacker. At last,
the stacked stockpile with mineral composition knowledge
is produced for the potential dividing of voxels with custom
shape as shown in Figure 3.
Another study was conducted by Lu and Myo in 2010
using stockpile information produced from SPSim simulator
[7-8]
. They proposed the approach in which stockpile is
divided into cubic voxels with specific quantity and mineral
composition percentage for each voxel. The study was
focused on identifying optimal stockpile voxels to fulfil the
demand in terms of quantity and quality considering the
BWR minimum movement. The objective function for
binary integer programming optimization was defined based
on the BWR minimum movement while constraining to the
required quality and quantity. The case study was conducted
for three consecutive demand quantities with specific
composition percentage requirements using Xpress-MP
optimization software. The resulted quantity and quality

Based on the review of literatures, it is discovered that

the profile of the stockpile voxel is simply defined as the
cubic or unit volume. The specification of the voxel is set
without considering the parameters of the BWR. The voxel
profile is defined without taking into account the reclaiming
pattern of the BWR. The main objective of this paper is to
investigate the drawbacks of using cubic voxels following
the study of the BWR reclaiming pattern. Moreover, the
cutting trajectory is studied in deriving kinematics model of
the BWR. The remaining part of the paper is organized as
follows. Section 3 discusses about the BWR including the
configuration and the reclaiming patterns. The drawback of
the cubic voxel used in recent studies association with BWR
is investigated in Section 4. Section 5 presents the full
kinematics model of the BWR including the bucket wheel
which is treated as a four degree of freedom robotic
manipulator. Based on the kinematic model of the BWR,
the cutting trajectory is simulated in Section 6. Then the
paper is concluded with Section 7.

3. BWR
The large increase in the transportation of bulk material
enforced to design the worlds largest land based machines
in the late 19th and early 20th centuries based on the bucket
wheel technology from waterborne ladder dredgers concept
[10-11]
. Since then, bucket wheel system was used in stacking,
reclaiming and shipping bulk materials at ports and mine
sites, excavating and waste disposed in mines, and handling
ore at plants [10]. Bucket wheel stackers and reclaimers have
played major role in handling large tonnages of bulk
materials in the large Stockyards [11]. In this study, the BWR
is used for the purpose of reclaiming bulk material such as
coal and iron ore from stockpiles in Stockyard. The BWR is
available in many types depends on the configuration and
structure of the mechanisms. From all, the rail supported
and boom mounted BWR is chosen in this study. The
typical BWR used in the Stockyard is shown in Figure 4. It
is one of the largest machines on earth with 25m height,
50m in length and 13,000 tonnes in weight. A rotating
wheel with buckets is attached at the end of a 45m boom to
scoop material [12]. The conveyor belt is fixed in the middle
section of the boom to carry materials fallen from buckets
[13]
.

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Fig. 4. Bucket wheel reclaimer from ThyssenKrupp Robins [14]

Fig. 6. Trajectory of a BWR boom tip [17]

A. Configuration of a BWR
BWR can be classified as a serial manipulator in robotic
fields [12, 15]. The schematic diagram of a BWR with
stockpile is shown in Figure 5. The prismatic joint
represents for the translation motion of the main body
moving on the rectilinear rail. The slewing motion is rotated
about the Axis 2 for reclaiming whereas the luffing motion
is rotated on the Axis 3 for accessing lower bench of the
stockpile. Lu treated BWR as a three degree of freedoms
robot manipulator considering bucket wheel as an
end-effector [15]. However in this study, the BWR will be
treated as four degrees of freedom manipulator counting
bucket wheel as a link.

Moreover, the luffing motion is used to reclaim lower

layer bulk material from stockpiles. Because of the BWRs
luffing motion, the remaining shape of stockpile after
reclaiming partially is in ladder shape as shown in Figure 7.

Fig. 7. Remaining shape of a stockpile after reclaiming partially [18]

4. DRAWBACK OF CUBIC VOXELS

Fig. 5. Schematic diagram of BWR and stockpile [15]

B. Reclaiming method of a BWR

A BWR reclaims bulk material from stockpiles using
either bench reclaiming or pilgrim step reclaiming approach
[16]
. During the bench reclaiming process, all the stockpile
layers are completely reclaimed one by one from top to
bottom. The whole layer of the stockpile is reclaimed before
the boom is luffed down to the next layer. The bench
reclaiming approach is used when the entire layer or
stockpile is required to reclaim [16]. In pilgrim step
approach, the only portion of the stockpile layer is
reclaimed instead of reclaiming whole layer. The pilgrim
step approach is used when the material from one end of the
stockpile is required to reclaim first or only portions of the
particular stockpile is required to reclaim [16].
In both reclaiming approaches, the BWR reclaims
material with slewing motion which is a circular rotational
motion of the boom. The slewing trajectory of the BWRs
boom tip with translation movement as seen from top view
is shown in Figure 6. In this figure, AB curve is the
slewing motion path from position O and A'B' is the
slewing motion path after translating distance d1 to
position O'.

The expectation of steel producers has increased over

the years to receive iron ore in required quantity and
specified quality. The voxel-based approach was introduced
in recent studies to improve in meeting customers request
in terms of quantity and quality. In visual model as shown
in Figure 2, it is appealing that the specification of the
demand can be fulfilled in combining certain voxels before
reclaiming physically. However, it is concerned that
whether the actual reclaimed volume is achieved as
promised in a visual reclaiming process. The investigation
is carried out here to compare the reclaiming profile of
BWR with cubic voxels in actual reclaiming.
The reclaiming profile of the BWR in reclaiming cubic
voxel is shown in Figure 8. It shows that there is huge
disagreement between the reclaiming profile and cubic
voxel which leads to poor estimations in terms of quantity
and quality. It will be compensated from other voxels if the
whole stockpile or whole bench is reclaimed as in bench
reclaiming method. However, certain portions of the
stockpile are required to be reclaimed in most of the cases
to meet the demand requirement as practiced in pilgrim step
method.
Furthermore, Figure 9 shows the disagreement between
the BWR reclaiming curve and cubic voxels from top view.
In that figure, stockpile is composed with labelled cubic
voxels available for reclaiming. As an example, voxel No. 1
and 2 are necessary to reclaim to meet the customer
demand. So the BWR attempts to reclaim the required voxel
1 and 2 with its reclaiming path as shown in Figure 6.

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However, it can be seen that only the portion of voxel 1 and

2 are able to be reclaimed with a circular reclaiming path.
Moreover, the extra portion of the vessel 3 is reclaimed
affecting the accuracy of the reclaiming volume. In other
words, some unwanted portions of voxels are reclaimed
and/or some necessary portions of voxels are left behind. It
is observed that the optimal accuracy of reclaiming has not
been able to achieve with cubic voxels for BWR reclaiming.
So the concern is mounting that what shapes of the voxels
should be most suitable for the BWR reclaiming. The other
approach is defining smaller size voxels to improve the
accuracy of reclaiming. It is believed that it will increase the
accuracy of output to some extent but there will be some
drawbacks attached to it. The stockpile is a large entity and
the BWR reclaims high volume at single movement.
Defining smaller size of voxel will make computation very
heavy for voxelization and also it is not practical for the
huge reclaiming nature of the operation. It is realized that
the best approach of defining the optimal shape of voxel
will be a replicate of BWR reclaiming trajectory. The
optimal accuracy of reclaiming will be achieved when the
BWR reclaims same trajectory with voxel boundary. To
study the BWR reclaiming trajectory, the kinematics model
of the BWR including bucket wheel is derived in the next
section.

57

an enlargement of the bucket wheel from Figure 10. Fixed

Frame 0 is attached to the base of the rail considering as the
world coordinate. Frame 1 is attached to the main body of
the BWR whereas Frame 2 and 3 are attached at the joint of
the boom. Frame 3 is fixed at the end of the boom whereas
Frame 4 attached at the centre of the bucket wheel. The last
Frame b is attached at one of the buckets tip.

Fig. 10. BWR skeleton with assigned frames using modified D-H
representation

Fig. 8. BWR reclaiming voxel profile with cubic voxel

Fig. 11. Enlargement of bucket wheel with assigned frames

Fig. 9. Reclaiming curve of BWR and cubic voxels.

5. KINEMATICS OF THE BWR

Kinematics is the study of motion which includes
position, velocity and acceleration without considering the
forces that cause it [19]. However, this study will focus only
on the position and orientation of the BWR kinematics.
Among the links of the BWR, the bucket wheel is the actual
link which is in contact with the material in reclaiming. For
that reason, the tip of the buckets on the BWR bucket wheel
is chosen as the desired position point to find the kinematics
equation. The coordinate frames are assigned to the BWR
skeleton as shown in Figure 10 using modified
Danevit-Hartennberg (D-H) notation [19]. Figure 11 shows

Where,
2 = slewing angle between X2 and X1 measured about Z1.
3 = luffing angle between X3 and X2 measured about Z2.
b= bucket wheel angle between Xb and X5 measured about
Z5.
d1= translated distance between X1 and X0 measured along
Z0.
r = radius of the bucket wheel
L2, L3, L4, L5, h and k are distances between respected
frames and are constant parameters. The value of the
constant parameters varies depends on the type and
dimension of BWR. On the other hand, d1, 2, 3 and b are
variable parameters representing translating, slewing,
luffing and bucket wheel rotation motions.
The transformation matrix for adjacent coordinate
frames, i and i-1 using modified D-H representation is given
by [19]:

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58

sin i
cos i
sin cos
cos i cos i 1
i
i 1
i 1

iT
sin i sin i 1 cos i sin i 1

0
0

0
sin i 1
cos i 1
0

ai 1

sin i 1di
cos i 1di

6. BWR CUTTING TRAJECTORY

(1)

20

15

10

0
0
-20

50
40

-40

In referring the kinematics equations, the joint

parameters involved are translational distance (d1), luffing
angle (3), slewing angle (2) and bucket wheel angle (b).
Among them, the bucket wheel angle, which accounts for
contact region between the bucket wheel and stockpile, is
investigated here to simulate the cutting trajectory.
Schneidersmann indicated that the filling process begins at
0= 0 degree as shown in Figure 13 when the bucket dips
into the material [20]. Then at 1= 90 degree, the filling
process of the bucket is completed. Hence, the bucket wheel
angle is taken as the range from 0 to 90 degrees for cutting
trajectory simulation.

30
20

-60
-80

10
0

Fig. 12. Motion trajectory of a bucket wheel

The transformation matrix from the bucket wheel frame

to the world coordinate is derived by multiplying
transformation matrices from Frame 0 to Frame b:

mx nx ox
m n o
0
Tb 0T1 1T2 2T3 3T4 4T5 5Tb y y y
mz nz oz

0 0 0

xb
yb O P

zb 0 1

(2)

Where, O represents the orientation part and P represents

the position part of the transformation matrix. The
orientation information of the bucket tip is:

mx sin 2 cos 3 cos b sin 2 sin 3 sin b

my sin 3 cos b cos(3 ) sin b

mz cos 2 cos 3 cos b cos 2 sin 3 sinb

nx sin 2 cos 3 sinb sin 2 sin 3 cos b
n y sin 3 sin b cos 3 cos b

Fig. 13. Three phases of the bucket wheel cycle [20]

The cutting trajectory of the BWR is modelled as:

xb r sin 2 cos 3 cos(0, 2 ) r sin 2 sin 3 sin(0, 2 ) h cos 2

k sin 2 cos 3 sin 2 ( L5 cos 3 L4 )
yb r sin 3 cos(0, 2 ) r cos 3 sin(0, 2 ) L2

L3 k sin 3 L5 sin 3
z b r cos 2 cos 3 cos(0, 2 ) r cos 2 sin 3 sin(0, 2 )

(3)

(5)

h sin 2 k cos 2 cos 3 L5 cos 2 cos 3

L4 cos 2 d1

nz cos 2 cos 3 sin b cos 2 sin3 cos b

ox cos 2
oy 0
oz sin 2
Whereas, the kinematics model of the BWR at the tip of
the bucket is:
xb r sin 2 cos 3 cos b r sin 2 sin 3 sin b h cos 2
k sin 2 cos 3 sin 2 ( L5 cos 3 L4 )
yb r sin 3 cos b r cos 3 sin b L2 L3
k sin 3 L5 sin 3
zb r cos 2 cos 3 cos b r cos 2 sin 3 sin b
(4)
h sin 2 k cos 2 cos 3 L5 cos 2 cos 3
L4 cos 2 d1
Link dimensions of the commonly used BWRs, L2=6m,
L3=5m, L4=5m, L5=50m, h=0.5m and k=0.5m, are used in
this study for kinematics model. Using the BWR kinematics
model, the motion trajectory of the bucket is simulated as
shown in Figure 12.

The luffing angle (3) is taken as -20 degree whereas

slewing angle range (2) is taken as (0, 90) degree for
simulation. The resulted cutting trajectory is shown in Fig.
14. In that figure, the dotted curve is the cutting trajectory
of the BWR at translation distance d1= 0 and the solid curve
is the cutting trajectory after translated for d 1=10m.
Moreover, the upper boundary and lower boundary of
cutting trajectory has a different curvature because of the
luffing motion involved. In defining the profile of voxel,
minimum translated distance of the BWR can be used as the
width of the voxel. The boundary of the voxel can be
defined using slewing curve of the BWR. The influence of
the BWR kinematic in defining the voxel profile will
produce non-regular shape contributing difficulty in volume
computation.
Based on the cutting profile of the BWR, the potential
shape of a voxel is shown in Figure 15. The immediate
future study covers introducing the new voxel shape to
voxelize the stockpile.

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59

REFERENCES
[1]

[2]

[3]
[4]

[5]

Fig. 14. Cutting trajectory of BWR for the given parameter

[6]
20

15

10

[7]
5

0
0
-20

[8]

50
40

-40

30
20

-60
-80

10
0

Fig. 15. Potential voxel profile

7.

[9]

CONCLUSION

The shortcomings of the cubic voxels used in previous

studies were investigated and demonstrated the
disagreement with the BWR reclaiming trajectories.
The accuracy in reclaiming voxels certainly affects in
meeting the specification of the demand requested by
customers. It had motivated to introduce a new voxel shape
based on the kinematics of a BWR for optimal result.
The kinematics model of a BWR including bucket wheel
was derived treating BWR as a four degree of freedom
robotic manipulator. The contact region between stockpile
and bucket wheel was examined to simulate the cutting
trajectory of the BWR for the given parameters.
Besides, the potential voxel shapes are revealed and
deserve further investigaions in future study. The
achievement of cutting trajectory in this study will assist in
defining the optimal profile of the voxel in future study.

[10]

[11]

[12]

[13]

[14]

[15]

ACKNOWLEDGMENT
The authors would like to thank Australian Research
Council and Industry Partner, Matrix Group Lty Ltd. for the
in part financial and in-kind support through ARC Linkage
LP0989780 grant.

[16]

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Maung T. R. Myo is currently pursuing PhD

study in Mechanical Engineering at the
University of Adelaide, Australia. His research
interests include Robotics and Automation in
material reclaiming applications.

Tien-Fu Lu received his Bachelor and MS

of Science in Mechanical Engineering
from National Cheng Kung University,
Taiwan, followed by a PhD. in
Manufacturing
and
Mechanical
Engineering from University of South
Australia, Australia, in 1997. He is
currently a senior lecturer at the School of
Mechanical Engineering, University of
Adelaide. His research interests include
nano-positioning,
chemical
source
localization, robotics in mining and
agriculture.

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Cite this work as:

Maung Thi Rein Myo, and Tien-Fu Lu, "Investigation of
the Bucket Wheel Reclaimer's Cutting Trajectory to
Define Optimal Voxel Shape," TSEST Transaction on
Control and Mechanical Systems, Vol. 2, No. 2, Pp.
54-60, Feb., 2013.
TRANSACTION SERIES ON ENGINEERING SCIENCES AND TECHNOLOGIES (TSEST)