Oversized & Big Rock Detection System
for Mining & Quarries
Oversized rocks, often called big rocks or boulders on site, entering crushers and feeders are one of the most common causes of unplanned shutdowns in mining and quarry operations. A single boulder can block a crusher inlet, overload wear parts, or force rock-breaker intervention — turning normal production into an emergency.
The oversized rock and boulder detection system continuously monitors material on conveyors, at dump pockets, and under haul-truck discharge. It detects oversized rocks in real time and triggers alarms or control actions before a boulder reaches critical equipment.
This system is designed for real-time primary crusher feed protection in mining and quarry operations. A detailed explanation of how and where this detection is implemented is provided in the Installation & Sensing Technology section.
What the system does
The oversized rock and boulder detection system performs three core functions:
- Measures rock size in motion
Industrial cameras analyse material as it moves or is dumped, identifying individual rocks and estimating their size in real time. - Classifies oversized and big rock material
Rocks that exceed configured limits are identified as boulders before they reach critical equipment. - Triggers plant response
When a boulder is detected, the system can alert operators, stop or isolate feed via PLCs, and issue SMS or phone-call notifications to on-shift personnel.
This turns uncontrolled crusher disruptions into controlled process events, reducing unplanned downtime, wear-part damage, and maintenance cost. The full operational and financial impact of oversized rocks is detailed in the Ausfallzeiten der Brechanlage vermeiden section.
Why this matters
Crushers and feeders are designed for a defined maximum feed size. When oversized rocks enter the system, they lead to:
- Blockages and bridging
- Drive overloads and trips
- Rock-breaker intervention
- Accelerated wear and equipment damage
- Lost production
Stopping these events before they reach the crusher is far more effective than reacting after a jam has already occurred.
Where detection is applied
The oversized rock and boulder detection system can be installed wherever oversized material enters or moves through the plant:
- Truck tipping and dump pockets
- Conveyor belts and transfer points
- Apron and vibrating feeders
- Crusher infeed chutes
This allows oversized rocks to be intercepted before they reach equipment that cannot handle them. The engineering reasons why these locations provide the most reliable measurement are described in the Installation & Sensing Technology page.
Integration into plant automation
The system connects directly to plant control systems, including:
- PLCs and interlock logic
- Conveyor and feeder controls
- Crusher feed systems
- Operator HMIs
- SMS and phone-call notifications
This allows boulder detection to become part of standard operating logic rather than a stand-alone warning system.
Built for industrial operation
The system uses industrial-grade cameras, controlled lighting, and rugged mounting to operate reliably in dust, vibration, and variable lighting conditions typical of mines and quarries.
Operational impact
Real-time oversized rock and boulder detection allows operations to:
- Prevent crusher blockages
- Reduce rock-breaker use
- Protect belts, feeders, and liners
- Maintain stable throughput
- Reduce unplanned downtime
It is a direct way to protect one of the most critical assets in any material handling process. A breakdown of the production, maintenance, and safety impact of boulder-related stoppages is provided in Ausfallzeiten der Brechanlage vermeiden.
FAQ — Oversized Rock & Boulder Detection System
How do you detect oversized rocks on a conveyor?
A camera mounted above the belt captures continuous images of the material stream. Image analysis identifies individual rocks and calculates their size relative to configured limits.
Can detection be used on truck dump points?
Yes. The oversized rock and boulder detection system can be mounted above dump pockets or tipping grids to analyse material as it is discharged from haul trucks.
How fast does the system react?
Detection and alarms occur in fractions of a second, allowing feed to be stopped or diverted before a boulder reaches the crusher or feeder.
What happens when a boulder is detected?
The system can issue an operator alert, stop a conveyor or feeder, activate PLC interlocks, and send SMS or phone-call notifications to the relevant on-shift personnel so that action is taken without delay.
Does this require changes to blasting or mining practice?
No. The oversized rock and boulder detection system works with existing material handling and blasting practices. It adds a protection layer at the process level.
What determines the boulder size limit?
Limits are configured based on crusher opening, feeder capacity, or chute geometry, and can be adjusted as operating conditions change.
Can the system be expanded later?
Yes. Additional cameras or detection points can be added to extend protection to other parts of the material handling chain.